Fabrication Method of Semiconductor Device and Semiconductor Device

ABSTRACT

A high-yield fabricating method of a semiconductor device including a peeling step is provided. 
     A peeling method includes a step of stacking and forming a first material layer and a second material layer over a substrate and a step of separating the first material layer and the second material layer from each other. The second material layer is formed over the substrate with the first material layer therebetween. The first material layer includes a first compound layer in contact with the second material layer and a second compound layer positioned closer to the substrate side than the first compound layer is. The first compound layer has the highest oxygen content among the layers included in the first material layer. The second compound layer has the highest nitrogen content among the layers included in the first material layer. The second material layer includes a resin. In the step of separating, the first material layer and the second material layer are separated from each other by irradiation of an interface between the first material layer and the second material layer or the vicinity of the interface with light.

This application is a continuation of copending U.S. application Ser.No. 16/493,104, filed on Sep. 11, 2019 which is a 371 of internationalapplication PCT/IB2018/051417 filed on Mar. 6, 2018 which are allincorporated herein by reference.

TECHNICAL FIELD

One embodiment of the present invention relates to a peeling method, afabrication method of a semiconductor device, and a fabrication methodof a display device. One embodiment of the present invention relates toa semiconductor device and a display device.

Note that one embodiment of the present invention is not limited to theabove technical field. Examples of the technical field of one embodimentof the present invention include a semiconductor device, a displaydevice, a light-emitting device, an electronic device, a lightingdevice, an input device (e.g., a touch sensor or the like), aninput/output device (e.g., a touch panel or the like), a driving methodthereof, and a manufacturing method thereof.

BACKGROUND ART

Display devices using organic electroluminescence (EL) elements orliquid crystal elements have been known. Other examples of displaydevices include a light-emitting device provided with a light-emittingelement such as a light-emitting diode (LED), and electronic paperperforming display with an electrophoretic method or the like.

The organic EL element has a basic structure in which a layer containinga light-emitting organic compound is provided between a pair ofelectrodes. When voltage is applied to the element, light emission fromthe light-emitting organic compound can be obtained. With the use ofsuch an organic EL element, thin, lightweight, high-contrast, andlow-power-consumption display devices can be achieved.

In addition, when a semiconductor element such as a transistor and adisplay element such as an organic EL element are formed over asubstrate (a film) having flexibility, a flexible display device can beachieved.

Disclosed in Patent Document 1 is a method for fabricating a flexibledisplay device in which a supporting substrate (a glass substrate)provided with a heat-resistant resin layer and electronic elements witha sacrificial layer therebetween is irradiated with laser light and theheat-resistant resin layer is peeled from the glass substrate.

PRIOR ART DOCUMENT Patent Document [Patent Document 1] JapanesePublished Patent Application No. 2015-223823 SUMMARY OF THE INVENTIONProblems to be Solved by the Invention

An object of one embodiment of the present invention is to provide anovel peeling method, a novel fabrication method of a semiconductordevice, or a novel fabrication method of a display device. An object ofone embodiment of the present invention is to provide a peeling method,a fabrication method of a semiconductor device, or a fabrication methodof a display device each having a low cost and a high mass productivity.An object of one embodiment of the present invention is to provide ahigh-yield peeling method. An object of one embodiment of the presentinvention is to fabricate a semiconductor device or a display deviceusing a large-sized substrate. An object of one embodiment of thepresent invention is to fabricate a semiconductor device or a displaydevice at low temperatures.

An object of one embodiment of the present invention is to provide adisplay device with low power consumption. An object of one embodimentof the present invention is to provide a display device with highreliability. An object of one embodiment of the present invention is toreduce the thickness or weight of a display device. An object of oneembodiment of the present invention is to provide a display devicehaving flexibility or a curved surface. An object of one embodiment ofthe present invention is to provide a display device less likely to bebroken. An object of one embodiment of the present invention is toprovide a novel display device, a novel input/output device, a novelelectronic device, or the like.

Note that the descriptions of these objects do not disturb the existenceof other objects. One embodiment of the present invention does not needto achieve all the objects. Other objects can be derived from thedescriptions of the specification, the drawings, and the claims.

Means for Solving the Problems

One embodiment of the present invention is a method for fabricating asemiconductor device including a step of stacking and forming a firstmaterial layer and a second material layer over a substrate and a stepof separating the first material layer and the second material layerfrom each other. The second material layer is formed over the substratewith the first material layer therebetween. The first material layerincludes a first compound layer in contact with the second materiallayer and a second compound layer positioned closer to the substrateside than the first compound layer is. The first compound layer has thehighest oxygen content among the layers included in the first materiallayer. The second compound layer has the highest nitrogen content amongthe layers included in the first material layer. The second materiallayer includes a resin. In the step of separating, the first materiallayer and the second material layer are separated from each other byirradiation of an interface between the first material layer and thesecond material layer or the vicinity of the interface with light.

One embodiment of the present invention is a method for fabricating asemiconductor device including a step of forming a first material layerover a substrate, a step of forming a second material layer over thefirst material layer, a step of heating the first material layer and thesecond material layer in a stacked state, and a step of separating thefirst material layer and the second material layer from each other. Inthe step of heating, a first compound layer in contact with the secondmaterial layer and a second compound layer positioned closer to thesubstrate side than the first compound layer is are formed in the firstmaterial layer. The first compound layer has the highest oxygen contentamong the layers included in the first material layer. The secondcompound layer has the highest nitrogen content among the layersincluded in the first material layer. The second material layer includesa resin. In the step of separating, the first material layer and thesecond material layer are separated from each other by irradiation of aninterface between the first material layer and the second material layeror the vicinity of the interface with light.

One embodiment of the present invention includes a step of forming afirst material layer over a substrate, a step of heating the firstmaterial layer at a first temperature, a step of forming a secondmaterial layer over the first material layer heated at the firsttemperature, a step of heating the first material layer and the secondmaterial layer in a stacked state at a second temperature, and a step ofseparating the first material layer and the second material layer fromeach other. The first temperature is higher than the second temperature.In the step of heating at the first temperature, the first compoundlayer in contact with the second material layer and the second compoundlayer positioned closer to the substrate side than the first compoundlayer is are formed in the first material layer. The first compoundlayer has the highest oxygen content among the layers included in thefirst material layer. The second compound layer has the highest nitrogencontent among the layers included in the first material layer. Thesecond material layer includes a resin. In the step of separating, thefirst material layer and the second material layer are separated fromeach other by irradiation of an interface between the first materiallayer and the second material layer or the vicinity of the interfacewith light.

The first material layer preferably includes a third compound layerpositioned closer to the substrate side than the second compound layeris.

The light for the irradiation preferably has a wavelength of greaterthan or equal to 180 nm and less than or equal to 450 nm. The light forthe irradiation preferably has a wavelength of 308 nm or around 308 nm.The irradiation with the light is preferably performed with the use of alaser apparatus. The irradiation with the light is preferably performedwith the use of a linear laser apparatus. An energy density of the lightis preferably greater than or equal to 300 mJ/cm² and less than or equalto 360 mJ/cm².

The absorptance of the light by a stacked-layer structure of thesubstrate, the first material layer, and the second material layer ispreferably higher than or equal to 80% and lower than or equal to 100%.

The first material layer preferably includes one or more of titanium,molybdenum, aluminum, tungsten, silicon, indium, zinc, gallium,tantalum, and tin. For example, it is preferable that the first compoundlayer include titanium oxide and the second compound layer includetitanium nitride or titanium oxynitride.

The second material layer preferably has a region with a thickness ofgreater than or equal to 0.1 μm and less than or equal to 5 μm. Thesecond material layer preferably includes a polyimide resin or anacrylic resin. The second material layer preferably has an averagetransmittance of light in a wavelength range of greater than or equal to450 nm and less than or equal to 700 nm of 70% or higher.

The step of separating is preferably performed while a liquid is fed tothe separation interface. The liquid preferably includes water.

The method for fabricating a semiconductor device of one embodiment ofthe present invention preferably includes a step of performing plasmatreatment on a surface of the first material layer and a step ofprocessing the first material layer subjected to the plasma treatment inan island-like shape. The second material layer is preferably formed tocover an end portion of the first material layer processed into theisland-like shape. In the plasma treatment, the surface of the firstmaterial layer is preferably exposed to an atmosphere including one orboth of oxygen and water vapor.

One embodiment of the present invention is a semiconductor deviceincluding a substrate, an adhesive layer, a resin layer, and afunctional layer that are stacked in this order. The functional layerincludes a transistor. Titanium is detected in surface analysis of asurface of the resin layer on the adhesive layer side. The surfaceanalysis is preferably performed by time-of-flight secondary ion massspectrometry.

For example, it is preferable that the transistor include a metal oxidein a channel formation region and the resin layer include a polyimideresin. Alternatively, it is preferable that the transistor include ametal oxide in the channel formation region and the resin layer includean acrylic resin. Alternatively, it is preferable that the transistorinclude hydrogenated amorphous silicon in the channel formation regionand the resin layer include a polyimide resin. Alternatively, it ispreferable that the transistor include hydrogenated amorphous silicon inthe channel formation region and the resin layer include an acrylicresin. Alternatively, it is preferable that the transistor includepolysilicon in the channel formation region and the resin layer includea polyimide resin. The substrate preferably has flexibility.Alternatively, it is preferable that the transistor include polysiliconin the channel formation region and the resin layer include an acrylicresin. The substrate preferably has flexibility.

Effect of the Invention

According to one embodiment of the present invention, a novel peelingmethod, a novel fabricating method of a semiconductor device, or a novelfabricating method of a display device can be provided. According to oneembodiment of the present invention, a peeling method, a fabricationmethod of a semiconductor device, or a fabrication method of a displaydevice each having a low cost and a high mass productivity can beprovided. According to one embodiment of the present invention, ahigh-yield peeling method can be provided. According to one embodimentof the present invention, a semiconductor device or a display deviceusing a large-sized substrate can be fabricated. According to oneembodiment of the present invention, a semiconductor device or a displaydevice can be fabricated at low temperatures.

According to one embodiment of the present invention, a display devicewith low power consumption can be provided. According to one embodimentof the present invention, a highly reliable display device can beprovided. According to one embodiment of the present invention, thethickness or weight of a display device can be reduced. According to oneembodiment of the present invention, a display device having flexibilityor a curved surface can be provided. According to one embodiment of thepresent invention, a display device less likely to be broken can beprovided. According to one embodiment of the present invention, a noveldisplay device, a novel input/output device, a novel electronic device,or the like can be provided.

Note that the description of these effects does not preclude theexistence of other effects. One embodiment of the present invention doesnot need to have all the effects. Other effects can be derived from thedescriptions of the specification, the drawings, and the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A-1C3 are cross-sectional views illustrating an example of afabrication method of a semiconductor device.

FIGS. 2A-2C2 are cross-sectional views illustrating an example of afabrication method of a semiconductor device.

FIGS. 3A and 3B are cross-sectional views illustrating an example of afabrication method of a semiconductor device.

FIGS. 4A-4E3 are cross-sectional views illustrating an example of afabrication method of a semiconductor device.

FIGS. 5A-5C3 are cross-sectional views illustrating an example of afabrication method of a semiconductor device.

FIGS. 6A-6D3 are cross-sectional views illustrating an example of afabrication method of a semiconductor device.

FIGS. 7A-7F are cross-sectional views illustrating examples of afabrication method of a semiconductor device.

FIG. 8 are schematic diagrams illustrating an example of a peelingmethod.

FIG. 9 are schematic diagrams illustrating an example of a peelingmethod.

FIG. 10 are schematic diagrams illustrating an example of a peelingmethod.

FIG. 11 is a schematic diagram illustrating an example of an interfacebetween a metal compound layer and a resin layer.

FIGS. 12A-12F3 are cross-sectional views illustrating an example of afabrication method of a light-emitting device.

FIGS. 13A-13C are cross-sectional views illustrating an example of afabrication method of a light-emitting device.

FIGS. 14A-14C are cross-sectional views illustrating an example of afabrication method of a light-emitting device.

FIGS. 15A and 15B are cross-sectional views illustrating an example of afabrication method of a display device.

FIGS. 16A-16D are cross-sectional views illustrating an example of afabrication method of a display device.

FIGS. 17A and 17B are cross-sectional views illustrating an example of afabrication method of a display device.

FIGS. 18A and 18B are cross-sectional views illustrating an example of afabrication method of a display device.

FIGS. 19A and 19B are cross-sectional views illustrating an example of afabrication method of a display device.

FIGS. 20A and 20B are cross-sectional views illustrating an example of afabrication method of a display device.

FIG. 21 is a drawing illustrating an example of a stack fabricationapparatus.

FIGS. 22A and 22B are drawings illustrating an example of a laserirradiation unit.

FIGS. 23A-23D are drawings illustrating examples of electronic devices.

FIGS. 24A-24E are drawings illustrating examples of electronic devices.

FIGS. 25A and 25B are observation photographs of cross sections ofsamples in Example 1.

FIGS. 26A-26C are observation photographs of cross sections of a samplein Example 1.

FIGS. 27A and 27B are XPS analysis results of samples in Example 1.

FIGS. 28A and 28B are observation photographs of cross sections ofsamples in Example 2.

FIGS. 29A and 29B are XPS analysis results of samples in Example 2.

FIG. 30 is an observation photograph of a cross section of a sample inExample 3.

FIGS. 31A and 31B are XPS analysis results of samples in Example 3.

FIGS. 32A-32C are observation photographs of cross sections of a samplein Example 4.

FIG. 33 is XPS analysis results of a sample in Example 4.

FIGS. 34A and 34B are observation photographs of cross sections ofsamples in Example 5.

FIG. 35 is ToF-SIMS measurement results of a sample in Example 6.

FIGS. 36A-36E2 are cross-sectional views illustrating fabricationmethods of samples in Examples 7 and 8.

FIGS. 37A-37D are SEM photographs of samples in Example 7.

FIG. 38 is I_(d)-V_(g) characteristics of a transistor in Example 8.

FIG. 39 is a cross-sectional view illustrating a transistor in Example8.

FIG. 40 is GBT stress test results of a transistor in Example 8.

FIGS. 41A-41D are display photographs of a display in Example 9.

FIG. 42(A) A drawing illustrating a structure of a display in Example 9.FIG. 42(B) and FIG. 42(C) Drawings illustrating a bend tester in Example9.

FIG. 43 is a display photograph of a display in Example 10.

MODE FOR CARRYING OUT THE INVENTION

Embodiments will be described in detail with reference to the drawings.Note that the present invention is not limited to the followingdescription, and it will be readily appreciated by those skilled in theart that modes and details of the present invention can be modified invarious ways without departing from the spirit and scope of the presentinvention. Thus, the present invention should not be construed as beinglimited to the descriptions in the following embodiments.

Note that in structures of the present invention described below, thesame portions or portions having similar functions are denoted by thesame reference numerals in different drawings, and a description thereofis not repeated. Furthermore, similar functions are denoted by the samehatch pattern and are not especially denoted by reference numerals insome cases.

In addition, the position, size, range, or the like of each structureillustrated in drawings does not represent the actual position, size,range, or the like in some cases for easy understanding. Therefore, thedisclosed invention is not necessarily limited to the position, size,range, or the like disclosed in the drawings.

Note that the terms “film” and “layer” can be interchanged with eachother depending on the case or circumstances. For example, the term“conductive layer” can be changed into the term “conductive film”. Asanother example, the term “insulating film” can be changed into the term“insulating layer”.

In this specification and the like, a metal oxide means an oxide of ametal in a broad expression. Metal oxides are classified into an oxideinsulator, an oxide conductor (including a transparent oxide conductor),an oxide semiconductor (also simply referred to as an OS), and the like.For example, in the case where a metal oxide is used in a semiconductorlayer of a transistor, the metal oxide is referred to as an oxidesemiconductor in some cases. That is, an OS FET can also be called atransistor including a metal oxide or an oxide semiconductor.

In this specification and the like, metal oxides containing nitrogen arealso collectively referred to as a metal oxide in some cases. Moreover,a metal oxide containing nitrogen may be referred to as a metaloxynitride.

Embodiment 1

In this embodiment, a peeling method and a fabrication method of asemiconductor device that are embodiments of the present invention willbe described with reference to FIG. 1 to FIG. 7.

<Peeling Method Overview>

In this embodiment, first, a first material layer and a second materiallayer are stacked over a substrate. Here, a metal compound layer isformed as the first material layer and a resin layer is formed as thesecond material layer. After that, the metal compound layer and theresin layer are separated from each other by light irradiation.

An interface between the metal compound layer and the resin layer or thevicinity thereof (also referred to as an interface or the vicinity ofthe interface) is preferably irradiated with the light. Furthermore, theinside of the metal compound layer may be irradiated with the light.Furthermore, the inside of the resin layer may be irradiated with thelight. Note that in this specification and the like, “an interfacebetween A and B or the vicinity thereof” and “an interface between A andB or the vicinity of the interface” each include at least the interfacebetween A and B and also include a range from the interface between Aand B to within 20% of the thickness of A or B.

The interface between the metal compound layer and the resin layer (aswell as the inside of the metal compound layer and the inside of theresin layer) is heated by the light irradiation, and the adhesion (oradhesiveness) between the metal compound layer and the resin layer canbe decreased. In addition, the metal compound layer and the resin layercan be separated from each other.

The metal compound layer preferably has a stacked-layer structure. Thelayers included in the stacked-layer structure preferably contain acommon metal.

The metal compound layer preferably includes a first compound layerwhich is in contact with the resin layer and a second compound layerwhich is positioned closer to the substrate side than the first compoundlayer is. The first compound layer preferably has the highest oxygencontent among the layers included in the metal compound layer. Thesecond compound layer preferably has the highest nitrogen content amongthe layers included in the metal compound layer.

It is preferable that the metal compound layer further include a thirdcompound layer that is closer to the substrate side than the secondcompound layer is. The third compound layer preferably contains oxygenand nitrogen.

It is considered that when such a metal compound layer including two orthree layers is used, distortion is caused inside the metal compoundlayer, which facilitates separation between the metal compound layer andthe resin layer. For example, the metal compound layer can have astructure in which a plurality of layers with different densities,stresses, or crystallinities are stacked.

Furthermore, when such a metal compound layer including two or threelayers is used, the absorptance of the light by the metal compound layersometimes increases. Furthermore, the absorption peak of the light canbe formed at the interface between the metal compound layer and theresin layer or in the vicinity thereof in some cases. This probablyfacilitates division of the bond between the metal compound layer andthe resin layer and separation between the metal compound layer and theresin layer.

Furthermore, the use of such a metal compound layer including two orthree layers sometimes increases thermal conductivity in a film-planedirection (which can also be referred to as a direction substantiallyperpendicular to a film thickness direction, a direction substantiallyparallel to the formation surface of the metal compound layer, or thelike). Here, when dust or the like is adhered to the light irradiationsurface of the substrate, nonuniformity occurs in the light irradiationin some cases. Peeling might be more difficult in a region that has notbeen sufficiently irradiated with light than in the other regions. Atthis time, owing to the metal compound layer including a layer havinghigh thermal conductivity in the film-plane direction, heat can beconducted to the region that has not been sufficiently irradiated withlight and failure in peeling can be reduced.

For the metal compound layer, a layer that includes one or more oftitanium, molybdenum, aluminum, tungsten, silicon, indium, zinc,gallium, tantalum, tin, hafnium, yttrium, zirconium, magnesium,lanthanum, cerium, neodymium, bismuth, and niobium can be used. Themetal compound layer can contain a metal, an alloy, and a compoundthereof (e.g., a metal oxide, a metal nitride, or a metal oxynitride).The metal compound layer preferably includes one or more of titanium,molybdenum, aluminum, tungsten, silicon, indium, zinc, gallium,tantalum, and tin.

For example, the first compound layer preferably includes titanium oxide(TiO_(a) (a>1)). The second compound layer preferably includes titaniumoxynitride (TiO_(b)N_(c) (b>0, c>0)) or titanium nitride (TiN_(d)(d>0)). The third compound layer preferably includes titanium oxide(TiO_(e) (0<e<a)).

The resin layer preferably includes a polyimide resin or an acrylicresin, for example.

The proportion of an element in a layer can be analyzed by X-rayphotoelectron spectroscopy (XPS), for example (hereinafter, referred toas XPS analysis). Specifically, depth-direction quantitative analysiscan be performed by performing XPS analysis while a sample is etched(e.g., performing ion beam sputtering and XPS analysis alternately). Inthis specification and the like, a case where the analysis is performedfrom the first compound layer side (from the layer closest to the resinlayer) is mainly described.

For example, the layers included in the metal compound layer can containa common metal and can each include a region where the proportion of themetal is higher than or equal to 30 atomic % and lower than or equal to70 atomic % in XPS analysis. It is particularly preferable that theproportion of the metal in the first compound layer be lower than thatin the other layers.

The metal compound layer preferably includes, in the first compoundlayer, a region having the highest proportion of oxygen in XPS analysis.The first compound layer preferably includes a region in which theproportion of oxygen is higher than or equal to 40 atomic % and lowerthan or equal to 70 atomic % in XPS analysis.

The metal compound layer preferably includes, in the second compoundlayer, a region having the highest proportion of nitrogen in XPSanalysis. The second compound layer preferably includes a region inwhich the proportion of nitrogen is higher than or equal to 10 atomic %and lower than or equal to 40 atomic % in XPS analysis.

The second compound layer preferably contains oxygen and nitrogen.Either of the proportion of oxygen and that of nitrogen may be higher inthe second compound layer. For example, the second compound layer caninclude a region in which the proportion of oxygen is higher than orequal to 5 atomic % and lower than or equal to 60 atomic % in XPSanalysis.

It is preferable that the third compound layer include a region in whichthe proportion of oxygen is lower than that in the first compound layerin XPS analysis. It is preferable that the third compound layer includea region in which the proportion of nitrogen is lower than that in thesecond compound layer in XPS analysis. Either of the proportion of ametal and that of oxygen may be higher in the third compound layer.

The first compound layer is preferably formed to have a sufficientthickness so that the surface state is made uniform. Specifically, thethickness of the first compound layer is preferably greater than orequal to 5 nm and less than or equal to 50 nm, further preferablygreater than or equal to 10 nm and less than or equal to 30 nm. When thethickness of the first compound layer is less than 5 nm, the compositionmight be nonuniform and the yield of peeling sometimes decreases.Furthermore, although the thickness of the first compound layer can belarger than 50 nm, it is preferably smaller than or equal to 50 nm inwhich case the film formation time can be short. It is also suggestedthat when the first compound layer is too thick, the influence thesecond compound layer has on the peeling interface and the vicinitythereof is reduced. This also means that the thickness of the firstcompound layer is preferably within the above range.

The thickness of the second compound layer is not particularly limitedand can be made thinner than the first compound layer, for example. Forexample, the second compound layer can have a thickness of greater thanor equal to 5 nm and less than or equal to 15 nm.

The thickness of the third compound layer is not particularly limited.For example, the thickness of the third compound layer is preferablygreater than or equal to 5 nm and less than or equal to 50 nm, furtherpreferably greater than or equal to 10 nm and less than or equal to 30nm. Although the thickness of the third compound layer can be greaterthan 50 nm, it is preferably less than or equal to 50 nm in which casethe film formation time can be short.

In the case where the peeling method of this embodiment is employed, ametal contained in the metal compound layer might be detected byanalyzing the surface of the resin layer exposed by peeling from themetal compound layer. For example, the surface of the resin layer can beanalyzed by XPS, secondary ion mass spectrometry (SIMS), time-of-flightsecondary ion mass spectrometry (ToF-SIMS), or the like. Specifically,in the case where a titanium compound is used for the metal compoundlayer, titanium can be detected from the surface of the resin layer.

Next, light irradiation will be described.

The light irradiation can be performed with a lamp, a laser apparatus,or the like.

The laser light irradiation is preferably performed with a linear laserapparatus. Laser apparatuses for the manufacturing lines for lowtemperature polysilicon (LTPS) and the like can be used, which enableseffective use of the apparatuses.

The linear laser apparatus condenses light in a long rectangular shape(the light is shaped into a linear laser beam) so that the interfacebetween the metal compound layer and the resin layer is irradiated withthe light.

The irradiation light preferably has a wavelength of greater than orequal to 180 nm and less than or equal to 450 nm. Further preferably,the irradiation light preferably has a wavelength of 308 nm or around308 nm.

In one embodiment of the present invention, it is preferable that theabsorptance of laser light by the stacked-layer structure of thesubstrate, the first material layer (e.g., the metal compound layer),and the second material layer (e.g., the resin layer) be high. Forexample, the absorptance of light with a wavelength of 308 nm by thestacked-layer structure is preferably higher than or equal to 80% andlower than or equal to 100%, further preferably higher than or equal to85% and lower than or equal to 100%. When most of the laser light isabsorbed by the stacked-layer structure, the yield of peeling can beincreased. Furthermore, a functional element can be inhibited from beingirradiated with the laser light, so that a decrease in the reliabilityof the functional element can be suppressed.

The energy density of the light is preferably greater than or equal to250 mJ/cm² and less than or equal to 400 mJ/cm², further preferablygreater than or equal to 250 mJ/cm² and less than or equal to 360mJ/cm².

In the case where the light irradiation is performed with a laserapparatus, the number of shots of laser light with which the sameportion is irradiated can be greater than or equal to 1 shot and lessthan or equal to 50 shots, preferably greater than 1 shot and less thanor equal to 10 shots, further preferably greater than 1 shot and lessthan or equal to 5 shots.

There are portions with low light intensity on both ends of the shortaxis of the beam. Accordingly, it is preferable that between one shotand the next shot be provided with a portion overlapping by greater thanor equal to the width of the portion with low light intensity.Therefore, the number of laser light shots is preferably greater than orequal to 1.1 shots, further preferably greater than or equal to 1.25shots.

Note that in this specification, the number of laser light shots refersto the number of times a point (a region) is irradiated with laserlight, and is determined by a beam width, scanning speed, a frequency,an overlap percentage, or the like. Furthermore, there is an overlappingportion between a pulse and another pulse when a linear beam is moved ina scanning direction, i.e., between one shot and the next shot, and theoverlapping ratio is referred to as an overlap percentage. Note that asthe overlap percentage becomes closer to 100%, the number of shots isincreased; as the overlap percentage becomes further from 100%, thenumber of shots is decreased; and as the scanning speed becomes higher,the number of shots is decreased.

That the number of shots of the laser light is 1.1 shots means thatthere is an overlap with a width of approximately one-tenth of the beambetween two successive shots, and can mean that the overlap percentageis 10%. Similarly, 1.25 shots mean that there is an overlap with a widthof approximately one-fourth of the beam between two successive shots,and can mean that the overlap percentage is 25%.

Here, the energy density of light used for irradiation in the lasercrystallization step of LTPS is high, e.g., greater than or equal to 350mJ/cm² and less than or equal to 400 mJ/cm². Furthermore, the number oflaser shots needs to be large, e.g., greater than or equal to 10 shotsand less than or equal to 100 shots.

Meanwhile, in one embodiment of the present invention, light irradiationfor separating the metal compound layer and the resin layer from eachother can be performed at a lower energy density or with a smallernumber of shots than that used in the laser crystallization step.Accordingly, the number of substrates which can be treated by a laserapparatus can be increased. Furthermore, a reduction in the runningcosts of a laser apparatus such as a reduction in the frequency ofmaintenance of the laser apparatus is possible. Consequently, thefabrication costs of semiconductor devices and the like can be reduced.

Furthermore, since the light irradiation is performed at a lower energydensity or with a smaller number of shots than that used in the lasercrystallization step, damage to the substrate caused by the laser lightirradiation can be reduced. Thus, the strength of the substrate is lesslikely to be reduced after the substrate is used once, and the substratecan be reused. Consequently, the costs can be reduced.

In this embodiment, the metal compound layer is placed between thesubstrate and the resin layer. With the use of the metal compound layer,in some cases, the light irradiation can be performed at a lower energydensity or with a smaller number of shots than that in the case wherethe metal compound layer is not used.

If a foreign matter such as dust is adhered to the light irradiationsurface of the substrate at the time of the light irradiation throughthe substrate, in some cases, nonuniformity occurs in the lightirradiation and part with low peelability is generated, leading to areduction in the yield of the step of separating the metal compoundlayer and the resin layer from each other. For that reason, it ispreferable that the light irradiation surface be cleaned before orduring the light irradiation. For example, the light irradiation surfaceof the substrate can be cleaned with an organic solvent such as acetone,water, or the like. Furthermore, the light irradiation may be performedwhile a gas is sprayed with an air knife. Thus, nonuniformity in thelight irradiation can be reduced and the yield of the separation can beincreased.

In the semiconductor device of this embodiment, the channel formationregion of the transistor preferably includes a metal oxide. A metaloxide can function as an oxide semiconductor.

In the case where low temperature polysilicon (LTPS) is used for achannel formation region of a transistor, the resin layer is required tohave heat resistance because a temperature of approximately 500° C. to550° C. needs to be applied. Furthermore, in some cases, the resin layeris required to have a larger thickness to relieve the damage in a lasercrystallization step.

In contrast, a transistor including a metal oxide in a channel formationregion can be formed at a temperature lower than or equal to 350° C., oreven lower than or equal to 300° C. Thus, the resin layer is notrequired to have high heat resistance. Accordingly, the uppertemperature limit of the resin layer can be low, widening the range ofchoices for materials.

Furthermore, the transistor including a metal oxide in the channelformation region does not need a laser crystallization step.Furthermore, in this embodiment, the light irradiation can be performedat a lower energy density or a smaller number of shots than that underthe condition used in the laser crystallization step. Furthermore, theresin layer is irradiated with the laser light without through thesubstrate in the laser crystallization step, whereas the resin layer isirradiated with the laser light through a formation substrate and ametal oxide layer in this embodiment. Since damage to the resin layer islow as described above, the resin layer can be thin. Since the resinlayer is not required to have high heat resistance and can be thinned,the fabrication cost of a device can be expected to significantly fall.In addition, as compared with the case of using LTPS, the steps can besimplified, which is preferable.

Note that the semiconductor device of one embodiment of the presentinvention is not limited to the structure in which the transistorincludes a metal oxide in the channel formation region. For example, inthe semiconductor device of this embodiment, the transistor can includesilicon in the channel formation region. As silicon, hydrogenatedamorphous silicon (a-Si:H) or crystalline silicon can be used. Ascrystalline silicon, microcrystalline silicon, polycrystalline silicon,single crystal silicon, and the like can be given.

LTPS is preferably used for the channel formation region.Polycrystalline silicon, e.g., LTPS, can be formed at a lowertemperature than single crystal silicon and has higher field effectmobility and higher reliability than amorphous silicon.

For the channel formation region, hydrogenated amorphous silicon ispreferably used. As compared to crystalline silicon, hydrogenatedamorphous silicon can be formed at low temperatures, has highproductivity, and can be easily fabricated with the use of a largesubstrate.

The resin layer may have a thickness greater than or equal to 0.1 μm andless than or equal to 5 μm. When the resin layer is formed to be thin,the semiconductor device can be fabricated at low costs. In addition,the semiconductor device can be lightweight and thin. Furthermore, thesemiconductor device can have higher flexibility.

The transmitting property with respect to visible light (also referredto as visible-light-transmitting property) of the resin layer is notparticularly limited. For example, the resin layer may be a layer havinga color or a transparent layer. When the resin layer is positioned onthe display surface side of the display device and the resin layer iscolored (has a color), a problem such as a reduced light extractionefficiency, a change in the color of the extracted light, or reduceddisplay quality might occur.

The resin layer can be removed with a wet etching apparatus, a dryetching apparatus, an ashing apparatus, or the like. In particular,removing the resin layer by ashing using oxygen plasma is favorable.

In this embodiment, the metal compound layer is provided between thesubstrate and the resin layer. Since the metal compound layer has afunction of absorbing light, the effect of light irradiation can beachieved even when the resin layer has low light absorptance.Accordingly, the resin layer having high visible-light transmittance canbe used. Therefore, even when the resin layer is located on the displaysurface side of the display device, high display quality can beachieved. Moreover, a step of removing the resin layer which is colored(has a color) to enhance the display quality can be omitted. Inaddition, the range of choices for the material of the resin layer iswidened.

The average value of the transmittance of light with a wavelengthgreater than or equal to 450 nm and less than or equal to 700 nm throughthe resin layer is preferably higher than or equal to 70% and lower thanor equal to 100%, further preferably higher than or equal to 80% andlower than or equal to 100%, still further preferably higher than orequal to 90% and lower than or equal to 100%. The average value of thetransmittance of light with a wavelength greater than or equal to 400 nmand less than or equal to 700 nm through the resin layer is preferablyhigher than or equal to 70% and lower than or equal to 100%, furtherpreferably higher than or equal to 80% and lower than or equal to 100%,still further preferably higher than or equal to 90% and lower than orequal to 100%.

The resin layer preferably has a high transmitting property with respectto visible light, in which case the light extraction efficiency does noteasily decrease even when the resin layer remains on the display surfaceside after peeling. An acrylic resin has a high transmitting propertywith respect to visible light and is thus suitable as a material for theresin layer. When the baking temperature of an acrylic resin is low, thetransmitting property with respect to visible light can be high. Thebaking temperature of an acrylic resin is preferably higher than orequal to 200° C. and lower than or equal to 350° C., and furtherpreferably higher than or equal to 250° C. and lower than or equal to300° C.

In this embodiment, the transistor or the like is formed at atemperature lower than or equal to the upper temperature limit of theresin layer. The heat resistance of the resin layer can be evaluated by,for example, heat-induced weight loss percentage, specifically, 5%weight loss temperature. In the peeling method of this embodiment andthe fabrication method of a semiconductor device of this embodiment, themaximum temperature in the process can be low. For example, in thisembodiment, the 5% weight loss temperature of the resin layer can behigher than or equal to 200° C. and lower than or equal to 650° C.,higher than or equal to 200° C. and lower than or equal to 500° C.,higher than or equal to 200° C. and lower than or equal to 400° C., orhigher than or equal to 200° C. and lower than or equal to 350° C. Thus,the range of choices for materials is widened. Note that the 5% weightloss temperature of the resin layer may be higher than 650° C.

Before or during the separation, a water-containing liquid is preferablyfed to the separation interface. Water present at the separationinterface further reduces adhesion or adhesiveness between the resinlayer and the metal compound layer and can reduce the force required forthe separation. Furthermore, feeding a water-containing liquid to theseparation interface sometimes weakens or cuts a bond between the resinlayer and the metal compound layer. A chemical bond with the liquid isutilized to cut a bond between the resin layer and the metal compoundlayer, which allows the separation to proceed. For example, in the casewhere a hydrogen bond is formed between the resin layer and the metalcompound layer, it can be assumed that feeding the water-containingliquid forms a hydrogen bond between the water and the resin layer orthe metal compound layer to cut the hydrogen bond between the resinlayer and the metal compound layer.

The metal compound layer preferably has low surface tension and highwettability with respect to a water-containing liquid. In that case, thewater-containing liquid can be distributed over the entire surface ofthe metal compound layer and can be easily fed to the separationinterface. Distribution of the water over the entire metal compoundlayer leads to uniform peeling.

The contact angle between the metal compound layer and thewater-containing liquid is preferably greater than 0° and less than orequal to 60°, further preferably greater than 0° and less than or equalto 50°. Note that when the wettability with respect to thewater-containing liquid is extremely high (e.g., when the contact angleis approximately 20° or less), it is sometimes difficult to obtain anaccurate value of the contact angle. The higher the wettability of themetal compound layer with respect to the water-containing liquid, thebetter; therefore, the wettability with respect to the water-containingliquid may be high enough to prevent an accurate value of the contactangle from being obtained.

The water-containing liquid present at the separation interface caninhibit an adverse effect of static electricity that is caused at thetime of separation on a functional element (e.g., breakage of asemiconductor element due to static electricity). Furthermore, staticelectricity on a surface of the functional layer which is exposed by theseparation may be removed with an ionizer or the like.

In the case where a liquid is fed to the separation interface, thesurface of the functional layer which is exposed by the separation maybe dried.

A peeling method will be specifically described below.

In this embodiment, a semiconductor device including a transistor willbe described as an example. The semiconductor device can be a flexibledevice by using a flexible material for a substrate. Note that oneembodiment of the present invention is not limited to the semiconductordevice and can be applied to a variety of devices such as asemiconductor device using a different functional element, alight-emitting device, a display device, and an input/output device.

Note that thin films (e.g., insulating films, semiconductor films, orconductive films) included in any of a variety of devices can be formedby a sputtering method, a chemical vapor deposition (CVD) method, avacuum evaporation method, a pulsed laser deposition (PLD) method, anatomic layer deposition (ALD) method, or the like. As the CVD method, aplasma-enhanced chemical vapor deposition (PECVD) method or a thermalCVD method may be used. As an example of the thermal CVD method, a metalorganic chemical vapor deposition (MOCVD) method may be used.

The thin films (e.g., insulating films, semiconductor films, orconductive films) included in any of a variety of devices can be formedby a method such as spin coating, dipping, spray coating, ink-jetting,dispensing, screen printing, offset printing, a doctor knife, slitcoating, roll coating, curtain coating, or knife coating.

When the thin films included in any of a variety of devices areprocessed, a lithography method or the like can be used for theprocessing. Alternatively, island-shaped thin films may be formed by afilm formation method using a shadow mask. Alternatively, ananoimprinting method, a sandblasting method, a lift-off method, or thelike may be used for the processing of the thin films. As aphotolithography method, there are a method in which a resist mask isformed over a thin film to be processed, the thin film is processed byetching or the like, and the resist mask is removed, and a method inwhich a photosensitive thin film is formed, and then exposed to lightand developed to be processed into a desired shape.

In the case of using light in the lithography method, any of an i-line(a wavelength of 365 nm), a g-line (a wavelength of 436 nm), and anh-line (a wavelength of 405 nm), or combined light of any of them can beused for light exposure. Besides, ultraviolet light, KrF laser light,ArF laser light, or the like can be used. Furthermore, light exposuremay be performed by liquid immersion light exposure technique.Furthermore, as the light used for the light exposure, extremeultra-violet light (EUV) or X-rays may be used. Furthermore, instead ofthe light used for the light exposure, an electron beam can also beused. It is preferable to use extreme ultra-violet light, X-rays, or anelectron beam because extremely minute processing can be performed. Notethat in the case of performing light exposure by scanning of a beam suchas an electron beam, a photomask is not needed.

For etching of thin films, a dry etching method, a wet etching method, asandblast method, or the like can be used.

<Peeling Method Example 1>

Here, a peeling method is described which includes a step of forming afirst material layer over a substrate; a step of forming a secondmaterial layer over the first material layer; a step of heating thefirst material layer and the second material layer in a stacked state;and a step of separating the first material layer and the secondmaterial layer from each other. The case where a semiconductor deviceincluding a transistor is fabricated by the peeling method is describedas an example here. In the heating step, the first compound layer whichis in contact with the second material layer and the second compoundlayer which is positioned closer to the substrate side than the firstcompound layer is are formed in the first material layer. The heatingstep can also serve as a step of curing the second material layer. Thus,the number of steps in manufacturing the semiconductor device can bereduced, and manufacturing cost can be reduced.

First, a metal layer 102 is formed over a formation substrate 101 (FIG.1(A)). The metal layer 102 is a layer to be a metal compound layer 105later.

The formation substrate 101 has rigidity high enough for easy transferand has heat resistance to the temperature applied in the fabricationprocess. Examples of a material that can be used for the formationsubstrate 101 include glass, quartz, ceramics, sapphire, a resin, asemiconductor, a metal, and an alloy. Examples of the glass includealkali-free glass, barium borosilicate glass, and aluminoborosilicateglass.

For the metal layer 102, a variety of metals and alloys can be used, forexample. For the metal layer 102, a layer that includes one or more oftitanium, molybdenum, aluminum, tungsten, silicon, indium, zinc,gallium, tantalum, tin, hafnium, yttrium, zirconium, magnesium,lanthanum, cerium, neodymium, bismuth, and niobium can be used. Themetal layer 102 preferably includes one or more of titanium, molybdenum,aluminum, tungsten, silicon, indium, zinc, gallium, tantalum, and tin.

The metal layer 102 further preferably has a thickness of greater thanor equal to 10 nm and less than or equal to 100 nm, and still furtherpreferably greater than or equal to 10 nm and less than or equal to 50nm. By forming the metal layer 102 with a thickness of greater than orequal to 10 nm, a decrease in the yield of peeling can be suppressed. Inaddition, the thickness of the metal layer 102 is preferably less thanor equal to 100 nm, further preferably less than or equal to 50 nm, inwhich case the film formation time can be short.

There is no particular limitation on a method for forming the metallayer 102. For example, the metal layer 102 can be formed by asputtering method, a plasma-enhanced CVD method, an evaporation method,a sol-gel method, an electrophoretic method, a spray method, or thelike.

Next, a first layer 122 is formed over the metal layer 102 (FIG. 1(B)).The first layer 122 is a layer to be a resin layer 123 later.

FIG. 1(B) illustrates an example in which the first layer 122 is formedover the entire surface of the metal layer 102 by a coating method. Oneembodiment of the present invention is not limited to this example and aprinting method or the like may be employed to form the first layer 122.The first layer 122 having an island-like shape, the first layer 122having an opening or an unevenness shape, or the like may be formed overthe metal layer 102.

A variety of resin materials (including resin precursors) can be used toform the first layer 122.

The first layer 122 is preferably formed using a thermosetting material.

The first layer 122 may be formed using a material with photosensitivityor a material without photosensitivity (also called a non-photosensitivematerial).

When a photosensitive material is used, the resin layer 123 can beformed to have a desired shape by removing part of the first layer 122by a lithography method using light.

The first layer 122 is preferably formed using a material containing apolyimide resin, a polyimide resin precursor, or an acrylic resin. Thefirst layer 122 can be formed using, for example, a material containinga polyimide resin and a solvent, a material containing a polyamic acidand a solvent, a material containing an acrylic resin and a solvent, orthe like. Note that a material containing a polyimide resin or apolyimide resin precursor is preferably used for the first layer 122, inwhich case the heat resistance can be relatively high. Meanwhile, amaterial containing an acrylic resin is preferably used for the firstlayer 122, in which case the transmitting property with respect tovisible light can be high. A polyimide resin and an acrylic resin areeach a material suitably used for a planarization film or the like ofvarious kinds of devices such as a semiconductor device and a displaydevice; thus, the film formation apparatus and the material can beshared. Thus, another apparatus and another material are not needed forachieving the structure of one embodiment of the present invention.Since the first layer 122 does not need a special material and can beformed using a resin material used for various kinds of devices such asa semiconductor device and a display device as described above, the costcan be reduced.

Other examples of resin materials which can be used to form the firstlayer 122 include an epoxy resin, a polyamide resin, a polyimide-amideresin, a siloxane resin, a benzocyclobutene-based resin, a phenol resin,and precursors of these resins.

The first layer 122 is preferably formed with a spin coater. With theuse of a spin coating method, a thin film can be uniformly formed over alarge-sized substrate.

The first layer 122 is preferably formed using a solution having aviscosity greater than or equal to 5 cP and less than 500 cP, furtherpreferably greater than or equal to 5 cP and less than 100 cP, stillfurther preferably greater than or equal to 10 cP and less than or equalto 50 cP. As the viscosity of the solution is lower, application isperformed more easily. In addition, as the viscosity of the solution islower, inclusion of air bubbles can be reduced more; thus, ahigh-quality film can be formed.

Alternatively, the first layer 122 can be formed by dipping, spraycoating, ink-jetting, dispensing, screen printing, offset printing, adoctor knife, slit coating, roll coating, curtain coating, or knifecoating, for example.

Next, heat treatment is performed in the state where the metal layer 102and the first layer 122 are stacked, so that the metal compound layer105 and the resin layer 123 are formed (FIG. 1(C1)).

By heating the metal layer 102, the metal compound layer 105 is formed.By heating the first layer 122, the resin layer 123 is formed.

Structure examples of the metal compound layer 105 are illustrated inFIGS. 1(C2) and 1(C3). The metal compound layer 105 illustrated in FIG.1(C2) has a three-layer structure, and the metal compound layer 105illustrated in FIG. 1(C3) has a two-layer structure. The metal compoundlayer 105 illustrated in FIGS. 1(C2) and 1(C3) includes a first compoundlayer 111 which is in contact with the resin layer 123 and a secondcompound layer 112 which is positioned closer to the formation substrate101 side than the first compound layer 111 is. As illustrated in FIG.1(C2), the metal compound layer 105 can further include a third compoundlayer 113 which is positioned closer to the formation substrate 101 sidethan the second compound layer 112 is. The metal compound layer 105 mayhave a stacked-layer structure of four or more layers.

The structure of the metal compound layer 105 can be checked bycross-sectional observation, or analysis in a depth direction (alsoreferred to as a thickness direction). For example, the number of layersstacked, thickness, and the like of the metal compound layer 105 can bechecked by cross-sectional observation using a scanning transmissionelectron microscope (STEM: scanning transmission electron microscopy), atransmission electron microscope (TEM), or the like. As described above,the proportion of an element in each layer can be checked by XPS.Alternatively, high-resolution TEM-energy dispersive X-ray spectroscopy(EDX) or the like can also be used.

The first compound layer 111 preferably has the highest oxygen contentamong the layers included in the metal compound layer 105. The secondcompound layer 112 preferably has the highest nitrogen content among thelayers included in the metal compound layer 105. The third compoundlayer 113 preferably contains oxygen and nitrogen. The above descriptioncan also be referred to for the details of the layers.

The metal compound layer 105 preferably has a thickness of, for example,greater than or equal to 10 nm and less than or equal to 100 nm, furtherpreferably greater than or equal to 10 nm and less than or equal to 50nm. Note that in the case where the metal compound layer 105 is formedusing the metal layer 102, the completed metal compound layer 105 issometimes thicker than the formed metal layer 102.

The heat treatment can be performed while a gas containing one or moreof oxygen, nitrogen, and a rare gas (e.g., argon) is supplied into achamber of a heating apparatus, for example. Alternatively, the heattreatment can be performed in an air atmosphere with the use of achamber of a heating apparatus, a hot plate, or the like.

The heat treatment is preferably performed while a nitrogen gas issupplied. In that case, nitrogen can be sufficiently contained in themetal compound layer 105.

When heating is performed in an air atmosphere or performed while a gascontaining oxygen is supplied, the resin layer 123 is sometimes coloredby oxidation to have a decreased transmitting property with respect tovisible light. This also means that heating is preferably performedwhile a nitrogen gas is supplied. In that case, the heating atmospherecan contain less oxygen than an air atmosphere; thus, oxidation of theresin layer 123 can be inhibited and the resin layer 123 can have anincreased transmitting property with respect to visible light.

By the heat treatment, gas components to be released (e.g., hydrogen,water, or the like) in the resin layer 123 can be reduced. Inparticular, the heating is preferably performed at a temperature higherthan or equal to the formation temperature of each layer formed over theresin layer 123. Thus, a gas released from the resin layer 123 in thefabrication process of the transistor can be significantly reduced.

For example, in the case where the formation temperature of thetransistor is lower than or equal to 350° C., a film to be the resinlayer 123 is preferably heated at a temperature higher than or equal to350° C. and lower than or equal to 450° C., further preferably higherthan or equal to 350° C. and lower than or equal to 400° C., stillfurther preferably higher than or equal to 350° C. and lower than orequal to 375° C. Thus, a gas released from the resin layer 123 in thefabrication process of the transistor can be significantly reduced.

The temperature of the heat treatment is preferably set to lower than orequal to the maximum temperature in fabricating the transistor. When thetemperature of the heat treatment is set to lower than or equal to themaximum temperature in fabricating the transistor, a manufacturingapparatus for the fabrication process of the transistor, for example,can also be utilized, which can reduce additional capital investment andthe like. As a result, the semiconductor device with reduced productioncosts can be obtained. When the formation temperature of the transistoris lower than or equal to 350° C., for example, the temperature of theheat treatment is preferably lower than or equal to 350° C.

The maximum temperature in fabricating the transistor is preferablyequal to the temperature of the heat treatment, in which case it ispossible to prevent the heat treatment from increasing the maximumtemperature in fabricating the semiconductor device and it is alsopossible to reduce the gas components to be released in the resin layer123.

Even when the heating temperature is relatively low, increasing thetreatment time sometimes achieves separability equivalent to that undera condition with a higher heating temperature. It is thus preferable toincrease the treatment time when the heating temperature cannot beincreased owing to the structure of the heating apparatus.

The duration of the heat treatment is preferably longer than or equal tofive minutes and shorter than or equal to 24 hours, further preferablylonger than or equal to 30 minutes and shorter than or equal to 12hours, still further preferably longer than or equal to one hour andshorter than or equal to six hours, for example. Note that the durationof the heat treatment is not limited thereto. For example, the durationof the heat treatment may be shorter than five minutes in the case wherethe heat treatment is performed by a rapid thermal annealing (RTA)method.

As the heating apparatus, it is possible to use a variety of apparatusessuch as an electric furnace and an apparatus for heating an object byheat conduction or heat radiation from a heating element such as aresistance heating element. For example, an RTA apparatus such as a gasrapid thermal anneal (GRTA) apparatus or a lamp rapid thermal anneal(LRTA) apparatus can be used. An LRTA apparatus is an apparatus forheating an object by radiation of light (an electromagnetic wave)emitted from a lamp such as a halogen lamp, a metal halide lamp, a xenonarc lamp, a carbon arc lamp, a high-pressure sodium lamp, or ahigh-pressure mercury lamp. A GRTA apparatus is an apparatus forperforming heat treatment by using a high-temperature gas. With an RTAapparatus, the treatment time can be shortened and thus the RTAapparatus is preferred for mass production. Furthermore, the heattreatment may be performed using an in-line heating apparatus.

Note that the heat treatment sometimes changes the thickness of theresin layer 123 from the thickness of the first layer 122. For example,in some cases, the volume decreases when the solvent that was containedin the first layer 122 is removed or when the density increases withproceeding curing, which makes the thickness of the resin layer 123smaller than that of the first layer 122.

Before the heat treatment, heat treatment (also referred to aspre-baking treatment) for removing the solvent contained in the firstlayer 122 may be performed. The temperature of the pre-baking treatmentcan be set as appropriate according to the material that is used. Forexample, it can be higher than or equal to 50° C. and lower than orequal to 180° C., higher than or equal to 80° C. and lower than or equalto 150° C., or higher than or equal to 90° C. and lower than or equal to120° C. Alternatively, the heat treatment may double as the pre-bakingtreatment, and the solvent contained in the first layer 122 may beremoved by the heat treatment.

The resin layer 123 has flexibility. The formation substrate 101 haslower flexibility than the resin layer 123 does.

The resin layer 123 preferably has a thickness greater than or equal to0.01 μm and less than 10 μm, further preferably greater than or equal to0.1 μm and less than or equal to 5 μm, still further preferably greaterthan or equal to 0.5 μm and less than or equal to 3 μm. By forming theresin layer thin, the semiconductor device can be fabricated at lowcosts. Furthermore, the semiconductor device can be lightweight andthin. Furthermore, the semiconductor device can have higher flexibility.With a solution having low viscosity, the resin layer 123 having a smallthickness can be easily formed. Note that the thickness of the resinlayer 123 is not limited thereto, and may be greater than or equal to 10μm. For example, the resin layer 123 may have a thickness greater thanor equal to 10 μm and less than or equal to 200 μm. The resin layer 123having a thickness greater than or equal to 10 μm is favorable becausethe rigidity of the semiconductor device can be increased.

The resin layer 123 preferably has a thermal expansion coefficientgreater than or equal to 0.1 ppm/° C. and less than or equal to 50 ppm/°C., further preferably greater than or equal to 0.1 ppm/° C. and lessthan or equal to 20 ppm/° C., still further preferably greater than orequal to 0.1 ppm/° C. and less than or equal to 10 ppm/° C. The lowerthe thermal expansion coefficient of the resin layer 123 is, the morethe generation of a crack in a layer included in a transistor or thelike and breakage of a transistor or the like which are caused owing tothe heating can be prevented.

Next, a functional layer 135 is formed over the resin layer 123 (FIG.2(A)).

For the functional layer 135, for example, an insulating layer and afunctional element can be provided. Examples of the functional elementinclude semiconductor elements such as a transistor; light-emittingelements such as an inorganic EL element, an organic EL element, and alight-emitting diode (LED); display elements such as a liquid crystalelement, an electrophoretic element, and a display element using microelectromechanical systems (MEMS); and a sensor element.

The functional layer 135 preferably includes an insulating layer. Theinsulating layer preferably has a function of blocking hydrogen, oxygen,and water that are released from the metal compound layer 105, the resinlayer 123, and the like in a later heating step.

The functional layer 135 preferably includes, for example, a siliconnitride film, a silicon oxynitride film, or a silicon nitride oxidefilm. For example, a silicon nitride film is formed by a plasma-enhancedCVD method using a film formation gas containing a silane gas, ahydrogen gas, and an ammonia (NH₃) gas. There are no particularlimitations on the thickness of the insulating layer. The thickness canbe, for example, greater than or equal to 50 nm and less than or equalto 600 nm, preferably greater than or equal to 100 nm and less than orequal to 300 nm.

Note that in this specification and the like, “silicon oxynitride” is amaterial that contains more oxygen than nitrogen in its composition.Moreover, in this specification and the like, “silicon nitride oxide” isa material that contains more nitrogen than oxygen in its composition.

Next, a protective layer is formed over the functional layer 135. Theprotective layer is a layer positioned on the outermost surface of thesemiconductor device. The protective layer preferably includes anorganic insulating film because it is possible to prevent the surface ofthe semiconductor device from being damaged or cracked.

FIG. 2(A) illustrates an example in which a substrate 146 is bonded ontothe functional layer 135, with the use of an adhesive layer 145.

For the adhesive layer 145, a variety of curable adhesives such as areactive curable adhesive, a thermosetting adhesive, an anaerobicadhesive, and a photocurable adhesive such as an ultraviolet curableadhesive can be used. Furthermore, an adhesive sheet or the like may beused.

For the substrate 146, for example, a polyester resin such aspolyethylene terephthalate (PET) or polyethylene naphthalate (PEN), apolyacrylonitrile resin, an acrylic resin, a polyimide resin, apolymethyl methacrylate resin, a polycarbonate (PC) resin, apolyethersulfone (PES) resin, a polyamide resin (e.g., nylon or aramid),a polysiloxane resin, a cycloolefin resin, a polystyrene resin, apolyamide-imide resin, a polyurethane resin, a polyvinyl chloride resin,a polyvinylidene chloride resin, a polypropylene resin, apolytetrafluoroethylene (PTFE) resin, an ABS resin, cellulose nanofiber,or the like can be used. For the substrate 146, a variety of materialssuch as glass, quartz, a resin, a metal, an alloy, and a semiconductorthat are thin enough to be flexible may be used.

Next, the irradiation with laser light 155 is performed (FIG. 2(B)). Thelaser light 155 is, for example, a linear laser beam with which scanningis performed from the left side to the right side in FIG. 2(B), and themajor axis is perpendicular to the scanning direction and the incidentdirection (from top to bottom). In the laser apparatus, the stack isplaced with the formation substrate 101 being on the upper side. Thestack is irradiated with the laser light 155 from the upper side of thestack (the formation substrate 101).

An interface between the metal compound layer 105 and the resin layer123 or the vicinity thereof is preferably irradiated with the laserlight 155 through the formation substrate 101 (see a processing region156 in FIG. 2(B)). Furthermore, the inside of the metal compound layer105 may be irradiated with the laser light 155 or the inside of theresin layer 123 may be irradiated with the laser light 155.

The metal compound layer 105 absorbs the laser light 155. The resinlayer 123 may absorb the laser light 155.

The absorptance of the laser light 155 by the stacked-layer structure ofthe formation substrate 101 and the metal compound layer 105 ispreferably higher than or equal to 50% and lower than or equal to 100%,further preferably higher than or equal to 75% and lower than or equalto 100%, still further preferably higher than or equal to 80% and lowerthan or equal to 100%. Most of the laser light 155 is absorbed by thestacked-layer structure, so that separation can be surely performed atthe interface between the metal compound layer 105 and the resin layer123. Furthermore, damage to the resin layer 123 due to light can bereduced.

The irradiation with the laser light 155 reduces adhesion oradhesiveness between the metal compound layer 105 and the resin layer123. The resin layer 123 is embrittled by the irradiation with the laserlight 155 in some cases.

As the laser light 155, light having a wavelength at which at least partof the laser light 155 is transmitted through the formation substrate101 and absorbed by the metal compound layer 105 is selected and used.The laser light 155 is preferably light in a wavelength range fromvisible light to ultraviolet light. For example, light with a wavelengthgreater than or equal to 180 nm and less than or equal to 450 nm,preferably greater than or equal to 200 nm and less than or equal to 400nm, further preferably greater than or equal to 250 nm and less than orequal to 350 nm, can be used.

The laser light 155 preferably has energy that is higher than the energygap of the metal compound layer 105. For example, the energy gap oftitanium oxide is approximately 3.2 eV. Thus, in the case where titaniumoxide is used for the metal compound layer 105, light preferably hasenergy higher than 3.2 eV.

In particular, an excimer laser having a wavelength of 308 nm ispreferably used because the productivity is high. The excimer laser ispreferable because the excimer laser is used also for lasercrystallization of LTPS, so that the existing LTPS manufacturing lineapparatus can also be used and new capital investment is not necessary.The energy of the light with a wavelength of 308 nm is approximately 4.0eV. That is, in the case where titanium oxide is used for the metalcompound layer 105, an excimer laser with a wavelength of 308 nm isfavorable. Furthermore, a solid-state UV laser (also referred to as asemiconductor UV laser), such as a UV laser having a wavelength of 355nm which is the third harmonic of an Nd:YAG laser, may be used. Asolid-state laser is preferable because the solid-state laser does notuse a gas and thus the running costs can be reduced compared with thoseof an excimer laser. Furthermore, a pulsed laser such as a picosecondlaser may be used.

In the case where linear laser light is used as the laser light 155, byrelatively moving the formation substrate 101 and a light source,scanning with the laser light 155 is performed and the irradiation withthe laser light 155 is performed across a region where separation isdesirably caused.

Here, when a foreign matter 158 such as dust is adhered to the lightirradiation surface of the formation substrate 101 as illustrated inFIG. 3(A), nonuniformity occurs in the light irradiation in some cases.FIG. 3(A) illustrates a comparative example where the resin layer 123 isformed over and in contact with the formation substrate 101. In FIG.3(A), a region 159 irradiated with light is discontinuous in a portiondirectly below the foreign matter 158, at an interface between theformation substrate 101 and the resin layer 123 or in the vicinitythereof. That portion has lower peelability than the other portions, andthus, there is a concern that the yield of the step of separating theformation substrate 101 and the resin layer 123 is lowered.

Meanwhile, in this embodiment, the metal compound layer 105 is formedbetween the formation substrate 101 and the resin layer 123. The metalcompound layer 105 preferably includes a layer having high thermalconductivity. For example, in the case where the metal compound layer105 illustrated in FIG. 3(B) has high thermal conductivity, heat isuniformly conducted to the entire metal compound layer 105 even when themetal compound layer 105 is partly heated. Therefore, even when theforeign matter 158 is adhered to the light irradiation surface of theformation substrate 101, heat is transferred to a portion of the metalcompound layer 105 that is shielded by the foreign matter 158, so thatformation of a portion having low peelability can be inhibited. Asillustrated in FIG. 3(B), at the interface between the metal compoundlayer 105 and the resin layer 123 or in the vicinity thereof, a heatedregion 154 is formed on an entire surface including a portion directlybelow the foreign matter 158. Note that the heated region 154 is formedin the metal compound layer 105 in some cases.

At the interface between the metal compound layer 105 and the resinlayer 123 or in the vicinity thereof, a region which is not irradiatedwith light may be provided in one place or a plurality of places. Theareas of the regions which are not irradiated with light are notparticularly limited and are each greater than or equal to 1 μm² andless than or equal to 1 cm², for example. The area of the region whichis not irradiated with light may be less than or equal to 1 μm² orgreater than or equal to 1 cm² in some cases.

Then, the formation substrate 101 and the resin layer 123 are separatedfrom each other. Since the adhesion or adhesiveness between the metalcompound layer 105 and the resin layer 123 is low, the separation occursat the interface between the metal compound layer 105 and the resinlayer 123 (FIG. 2(C1)). Furthermore, the separation occurs in theembrittled resin layer 123 in some cases.

The formation substrate 101 and the resin layer 123 can be separatedfrom each other by applying a perpendicular tensile force to the resinlayer 123, for example. Specifically, part of a top surface of thesubstrate 146 is suctioned and pulled up, whereby the resin layer 123can be peeled from the formation substrate 101.

Here, the separation can be performed easily when a water-containingliquid such as water or an aqueous solution is added to the separationinterface and the liquid penetrates into the separation interface.Furthermore, an adverse effect of static electricity caused during theseparation on the functional element such as a transistor (e.g.,breakage of a semiconductor element by static electricity) can besuppressed. FIG. 2(C2) illustrates an example in which a liquid is fedto the separation interface with a liquid feeding mechanism 157.

As the liquid to be fed, water (preferably pure water), a neutral,alkaline, or acidic aqueous solution, and an aqueous solution in which asalt is dissolved can be given. Furthermore, ethanol, acetone, and thelike can be given. Furthermore, a variety of organic solvents may alsobe used.

Before the separation, a separation trigger may be formed by separatingpart of the resin layer 123 from the formation substrate 101. Forexample, the separation trigger may be formed by inserting a sharpinstrument such as a knife between the formation substrate 101 and theresin layer 123. Alternatively, the separation trigger may be formed bycutting the resin layer 123 from the substrate 146 side with a sharpinstrument. Alternatively, the separation trigger may be formed by amethod using a laser, such as a laser ablation method.

In this embodiment, the metal compound layer 105 and the resin layer 123are stacked and irradiated with light. As a result, the adhesion oradhesiveness between the metal compound layer 105 and the resin layer123 can be lowered. Accordingly, the formation substrate 101 and theresin layer 123 can be easily separated from each other.

The use of the peeling method of this embodiment makes it possible toprovide a fabrication method of a semiconductor device or a peelingmethod each having a low cost and a high mass productivity. For example,since the formation substrate 101 (e.g., a glass substrate) or a stackincluding the formation substrate 101 and the metal compound layer 105can be repeatedly used multiple times in the peeling method of thisembodiment, the production costs can be reduced.

In the peeling method of this embodiment, the metal compound layer 105and the resin layer 123 that can be easily separated from each other bylight irradiation are used, so that the peeling can be performed with ahigh yield. Furthermore, the heating step for forming (curing) the resinlayer 123 forms the metal compound layer 105 at the same time and thus,an increase in the number of steps can be suppressed.

<Peeling Method Example 2>

In Peeling method example 1, the metal layer 102 was heated to form themetal compound layer 105. In this Peeling method example 2, the methodis mainly described in which at least part of the metal layer 102 isoxidized to form a layer 103 containing a metal oxide and the layer 103containing a metal oxide is heated to form the metal compound layer 105.The formation of the layer 103 containing a metal oxide enables reducingthe force required for peeling and increasing the yield of peeling.

In the following peeling method example, steps similar to those inPeeling method example 1 are not described in detail.

First, the metal layer 102 is formed over the formation substrate 101(FIG. 4(A)).

Next, at least part of the metal layer 102 is oxidized. FIG. 4(B)illustrates an example in which a surface of the metal layer 102 isirradiated with plasma 110. Thus, the layer 103 containing a metal oxideis formed (FIG. 4(C)).

The layer 103 containing a metal oxide includes a metal oxide. Asexamples of the metal oxide, titanium oxide (TiO_(x)), molybdenum oxide,aluminum oxide, tungsten oxide, indium tin oxide containing silicon(ITSO), indium zinc oxide, an In—Ga—Zn oxide, and the like can be given.

Besides, as the metal oxide, indium oxide, indium oxide containingtitanium, indium oxide containing tungsten, indium tin oxide (ITO), ITOcontaining titanium, indium zinc oxide containing tungsten, zinc oxide(ZnO), ZnO containing gallium, hafnium oxide, yttrium oxide, zirconiumoxide, gallium oxide, tantalum oxide, magnesium oxide, lanthanum oxide,cerium oxide, neodymium oxide, tin oxide, bismuth oxide, titanate,tantalate, niobate, and the like can be given.

In this Peeling method example 2, oxygen is introduced into the metallayer 102 after formation of the metal layer 102, to form the layer 103containing a metal oxide. At this time, only the surface of the metallayer 102 or the entire metal layer 102 is oxidized. In the former case,the introduction of oxygen into the metal layer 102 forms a structure inwhich a metal layer and a metal oxide layer are stacked.

The oxidation of the metal layer 102 can be performed by heating themetal layer 102 in an oxygen-containing atmosphere. It is preferablethat the metal layer 102 be heated while an oxygen-containing gas issupplied. The temperature at which the metal layer 102 is heated ispreferably higher than or equal to 100° C. and lower than or equal to500° C., further preferably higher than or equal to 100° C. and lowerthan or equal to 450° C., still further preferably higher than or equalto 100° C. and lower than or equal to 400° C., yet still furtherpreferably higher than or equal to 100° C. and lower than or equal to350° C.

The temperature at which the metal layer 102 is heated is preferably setto lower than or equal to the maximum temperature in fabricating thetransistor. In that case, the maximum temperature in fabricating thesemiconductor device can be prevented from increasing. When thetemperature at which the metal layer is heated is set to lower than orequal to the maximum temperature in fabricating the transistor, amanufacturing apparatus for the fabricating process of the transistor,for example, can also be utilized, which can reduce additional capitalinvestment and the like. As a result, the semiconductor device withreduced production costs can be obtained. When the formation temperatureof the transistor is lower than or equal to 350° C., for example, thetemperature of the heat treatment is preferably lower than or equal to350° C.

Alternatively, the metal layer 102 can be oxidized by performing radicaltreatment on the surface of the metal layer 102. In the radicaltreatment, the surface of the metal layer 102 is preferably exposed toan atmosphere containing at least one of an oxygen radical and a hydroxyradical. For example, plasma treatment is preferably performed in anatmosphere containing one or both of oxygen and water vapor (H2O).

The force required for separating the metal compound layer 105 and theresin layer 123 from each other can be reduced when hydrogen, oxygen, ahydrogen radical (H*), an oxygen radical (O*), a hydroxy radical (OH*),or the like is contained on the surface of the metal compound layer 105or in the metal compound layer 105, which will be described in detail inEmbodiment 2.

Performing radical treatment or plasma treatment on the surface of themetal layer 102 to oxidize the metal layer 102 eliminates the need for astep of heating the metal layer 102 at high temperatures. Accordingly,the maximum temperature in fabricating the semiconductor device can beprevented from increasing.

Alternatively, the layer 103 containing a metal oxide may be formed byforming a metal oxide film over the metal layer 102. For example, ametal oxide film is formed by a sputtering method while anoxygen-containing gas is supplied, whereby the layer 103 containing ametal oxide can be formed. Note that a metal oxide film may be formeddirectly on the formation substrate 101 without forming the metal layer102. Also in the case where the layer 103 containing a metal oxide isformed by formation of the metal oxide film, a surface of the layer 103containing a metal oxide is preferably subjected to radical treatment.In the radical treatment, the surface of the layer 103 containing ametal oxide is preferably exposed to an atmosphere containing at leastone kind among an oxygen radical, a hydrogen radical, and a hydroxyradical. For example, plasma treatment is preferably performed in anatmosphere containing one or more of oxygen, hydrogen, and water vapor(H2O).

As other introduction methods of oxygen, hydrogen, water, or the like,an ion implantation method, an ion doping method, a plasma immersion ionimplantation method, and the like can be used.

The layer 103 containing a metal oxide preferably has a thickness of,for example, greater than or equal to 10 nm and less than or equal to100 nm, further preferably greater than or equal to 10 nm and less thanor equal to 50 nm. Note that in the case where the layer 103 containinga metal oxide is formed using the metal layer 102, the completed layer103 containing a metal oxide is sometimes thicker than the formed metallayer 102.

The layer 103 containing a metal oxide preferably contains titaniumoxide or tungsten oxide. Titanium oxide is preferably used because thecost can be lower than that when tungsten oxide is used.

Next, the first layer 122 is formed over the layer 103 containing ametal oxide (FIG. 4(D)).

Next, heat treatment is performed in the state where the layer 103containing a metal oxide and the first layer 122 are stacked, so thatthe metal compound layer 105 and the resin layer 123 are formed (FIG.4(E1)).

By heating the layer 103 containing a metal oxide, the metal compoundlayer 105 is formed. By heating the first layer 122, the resin layer 123is formed.

Structure examples of the metal compound layer 105 are illustrated inFIGS. 4(E2) and 4(E3). The metal compound layer 105 illustrated in FIG.4(E2) has a three-layer structure, and the metal compound layer 105illustrated in FIG. 4(E3) has a two-layer structure. The metal compoundlayer 105 illustrated in FIGS. 4(E2) and 4(E3) includes the firstcompound layer 111 which is in contact with the resin layer 123 and thesecond compound layer 112 which is positioned closer to the formationsubstrate 101 side than the first compound layer 111 is. As illustratedin FIG. 4(E2), the metal compound layer 105 can further include thethird compound layer 113 which is positioned closer to the formationsubstrate 101 side than the second compound layer 112 is.

For the following steps, the step in FIG. 2(A) and the subsequent stepsin Peeling method example 1 can be referred to.

As described above, hydrogen, oxygen, a hydrogen radical (H*), an oxygenradical (O*), a hydroxy radical (OH*), and the like are contained on thesurface of the metal compound layer 105 or in the metal compound layer105 in Peeling method example 2. This can reduce the force required forseparating the metal compound layer 105 and the resin layer 123 fromeach other.

<Peeling Method Example 3>

In Peeling method example 1, the metal layer 102 was heated to form themetal compound layer 105. In this Peeling method example 3, the methodis mainly described in which the metal compound layer 105 is formed byheating the metal layer 102 and a metal nitride layer 104 in a stackedstate.

First, the metal layer 102 is formed over the formation substrate 101,and the metal nitride layer 104 is formed over the metal layer 102 (FIG.5(A)).

The metal layer 102 and the metal nitride layer 104 are preferablyformed using a common metal. The metal layer 102 and the metal nitridelayer 104 can be formed by, for example, a sputtering method. Forexample, the metal layer 102 can be formed using an argon gas as aprocess gas. For example, the metal nitride layer 104 can be formedusing a nitrogen gas as a process gas.

Next, the first layer 122 is formed over the metal nitride layer 104(FIG. 5(B)).

Note that before the first layer 122 is formed, plasma treatment may beperformed on the metal nitride layer 104 to form a layer containing ametal oxide. For example, a surface side of the metal nitride layer 104may be oxidized to form a structure in which the metal layer 102, themetal nitride layer 104, and a metal oxide layer are stacked from theformation substrate 101 side. The stacked-layer structure can beregarded as a layer containing a metal oxide.

Next, heat treatment is performed in the state where the metal layer102, the metal nitride layer 104, and the first layer 122 are stacked,so that the metal compound layer 105 and the resin layer 123 are formed(FIG. 5(C1)).

By heating the metal layer 102 and the metal nitride layer 104, themetal compound layer 105 is formed. By heating the first layer 122, theresin layer 123 is formed.

Structure examples of the metal compound layer 105 are illustrated inFIGS. 5(C2) and 5(C3). The metal compound layer 105 illustrated in FIG.5(C2) has a three-layer structure, and the metal compound layer 105illustrated in FIG. 5(C3) has a two-layer structure. The metal compoundlayer 105 illustrated in FIGS. 5(C2) and 5(C3) includes the firstcompound layer 111 which is in contact with the resin layer 123 and thesecond compound layer 112 which is positioned closer to the formationsubstrate 101 side than the first compound layer 111 is. As illustratedin FIG. 5(C2), the metal compound layer 105 can further include thethird compound layer 113 which is positioned closer to the formationsubstrate 101 side than the second compound layer 112 is.

For the following steps, the step in FIG. 2(A) and the subsequent stepsin Peeling method example 1 can be referred to.

As described above, the layer formed between the formation substrate 101and the resin layer 123 (the first layer 122) can be formed using any ofa variety of materials including metals.

<Peeling Method Example 4>

Here, a peeling method is described which includes a step of forming afirst material layer over a substrate; a step of heating the firstmaterial layer at a first temperature; a step of forming a secondmaterial layer over the first material layer heated at the firsttemperature; a step of heating the first material layer and the secondmaterial layer in a stacked state at a second temperature; and a step ofseparating the first material layer and the second material layer fromeach other. Here, the first temperature is higher than the secondtemperature. By heating at the first temperature, a first compound layerand a second compound layer that is positioned closer to the substrateside than the first compound layer is are formed in the first materiallayer. Heating the first material layer at a sufficiently hightemperature can increase the peelability between the first materiallayer and the second material layer. Meanwhile, the second temperaturecan be lower than the first temperature. Thus, high heat resistance isnot required for the material for the second material layer and therange of choices for the material is wide. When the temperature at whichthe second material layer is heated is low, the transmitting propertywith respect to visible light is less likely to decrease. When twoheating steps at different temperatures are performed in this manner,both high peelability and a high visible-light-transmitting property ofthe second material layer can be achieved.

First, the metal layer 102 is formed over the formation substrate 101(FIG. 6(A)).

Next, the metal layer 102 is heated at the first temperature to form themetal compound layer 105 (FIG. 6(B1)).

The first temperature is preferably higher than or equal to 200° C. andlower than or equal to 500° C., further preferably higher than or equalto 200° C. and lower than or equal to 450° C., for example.

Structure examples of the metal compound layer 105 are illustrated inFIGS. 6(B2) and 6(B3). The metal compound layer 105 illustrated in FIG.6(B2) has a three-layer structure, and the metal compound layer 105illustrated in FIG. 6(B3) has a two-layer structure. The metal compoundlayer 105 illustrated in FIGS. 6(B2) and 6(B3) includes the firstcompound layer 111 and the second compound layer 112 which is positionedcloser to the formation substrate 101 side than the first compound layer111 is. As illustrated in FIG. 6(B2), the metal compound layer 105 canfurther include the third compound layer 113 which is positioned closerto the formation substrate 101 side than the second compound layer 112is.

Next, the first layer 122 is formed over the metal compound layer 105(FIG. 6(C)).

Next, heat treatment is performed at the second temperature in a statewhere the metal compound layer 105 and the first layer 122 are stacked.By heating the first layer 122, the resin layer 123 is formed (FIG.6(D1)).

The second temperature is preferably higher than or equal to 100° C. andlower than or equal to 450° C., further preferably higher than or equalto 100° C. and lower than or equal to 400° C., still further preferablyhigher than or equal to 100° C. and lower than or equal to 350° C., forexample.

Structure examples of the metal compound layer 105 are illustrated inFIGS. 6(D2) and 6(D3). The structures of the metal compound layer 105are similar to those in FIGS. 6(B2) and 6(B3).

Objects of heating after formation of the first layer 122 include toremove the solvent from the first layer 122 (pre-baking treatment) andto cure the first layer 122 (post-baking treatment). These can beperformed at a temperature lower than that of the heat treatment forforming the metal compound layer 105. That is, the second temperaturecan be lower than the first temperature.

The temperature at which the first layer 122 (the resin layer 123) areheated can be low; thus, a material having low heat resistance can beused for the first layer 122 and the range of choices for the materialcan be widened. In addition, coloring of the resin layer 123 can beinhibited.

The condition of the heat treatment at the first temperature and that ofthe heat treatment at the second temperature can be set independently ofeach other. For example, not only the temperature but also theatmosphere, the kind of the gas, the time, or the like may be varied.

Note that it is preferable that the heat treatment at the firsttemperature and the heat treatment at the second treatment be eachperformed under a nitrogen atmosphere or with a nitrogen gas supplied.Thus, nitrogen can be sufficiently contained in the metal compound layer105. Moreover, oxidation of the resin layer 123 can be suppressed and ahigh visible-light-transmitting property can be maintained.

For the following steps, the step in FIG. 2(A) and the subsequent stepsin Peeling method example 1 can be referred to.

As described above, in one embodiment of the present invention, themaximum temperature applied to the resin layer 123 can be low and themetal compound layer 105 and the resin layer 123 can be easily separatedfrom each other. Thus, the yield of peeling can be increased while thevisible-light-transmitting property of the resin layer 123 ismaintained.

<Peeling Method Example 5>

In Peeling method example 5, the timing of surface treatment andprocessing of the metal layer 102 is mainly described. In the case whereboth surface treatment and processing are performed on the metal layer102, there are two possible methods: a method in which the processing isperformed after the surface treatment (Process 1) and a method in whichthe surface treatment is performed after the processing (Process 2).

Process 1 is described with reference to FIGS. 7(A1), 7(B1), 7(C1),7(D1), 7(E), and 7(F). Process 2 is described with reference to FIGS.7(A2), 7(B2), 7(C2), 7(D2), 7(E), and 7(F).

First, in each process, the metal layer 102 is formed over the formationsubstrate 101 (FIGS. 7(A1) and 7(A2)).

Next, in Process 1, the metal layer 102 is irradiated with the plasma110 as illustrated in FIG. 7(B1), whereby the layer 103 containing ametal oxide that is illustrated in FIG. 7(C1) is formed. Then, the layer103 containing a metal oxide is processed into an island-like shape(FIG. 7(D1)).

Meanwhile, in Process 2, the metal layer 102 is processed into anisland-like shape as illustrated in FIG. 7(B2). Then, the island-shapedmetal layer 102 is irradiated with the plasma 110 (FIG. 7(C2)), wherebythe island-shaped layer 103 containing a metal oxide is formed (FIG.7(D2)).

The peeling method of this embodiment can be conducted through eitherProcess 1 or Process 2. It is particularly preferable to use Process 1since the force required for peeling can be reduced as compared to thatin Process 2. This is probably because the discharging conditions duringthe plasma treatment are different between before and after theprocessing of the metal layer 102 into an island-like shape, leading toa difference in the oxidation state of the surface of the metal layer102. In other words, it can be considered that the metal layer 102 canbe oxidized more uniformly and the force required for the peeling can besmaller in the case where the metal layer 102 is oxidized before themetal layer 102 is processed into an island-like shape (in a statebefore the metal layer 102 is patterned).

The description of Peeling method example 2 and Embodiment 2 can bereferred to for the surface treatment such as the plasma treatment.

As a method for processing the metal layer 102 or the layer 103containing a metal oxide, dry etching, wet etching, or the like can beused.

Then, in each process, the first layer 122 is formed over theisland-shaped layer 103 containing a metal oxide (FIG. 7(E)).

Then, heat treatment is performed in a state where the layer 103containing a metal oxide and the first layer 122 are stacked, wherebythe metal compound layer 105 and the resin layer 123 are formed (FIG.7(F)). Examples of the structure of the metal compound layer 105 at thetime of FIG. 7(F) include the two-layer structure and the three-layerstructure illustrated in FIGS. 4(E2) and 4(E3).

For the following steps, the step in FIG. 2(A) and the subsequent stepsin Peeling method example 1 can be referred to.

Here, depending on the structure of the functional layer 135 formed overthe resin layer 123, the adhesion between the functional layer 135 andthe metal compound layer 105 might be low. Low adhesion between thefunctional layer 135 and the metal compound layer 105 causes filmseparation (also referred to as peeling) in a fabrication process of asemiconductor device, which brings a problem of a decrease in yield. Forexample, film separation is sometimes observed in the case where atitanium oxide film is used as the layer (the first compound layer)closest to the resin layer 123 side in the metal compound layer 105 andan inorganic insulating film such as a silicon oxide film or a siliconoxynitride film is used as the layer closest to the resin layer 123 sidein the functional layer 135.

Therefore, as illustrated in FIG. 7(F), the resin layer 123 preferablycovers an end portion of the island-shaped metal compound layer 105. Inthat case, a portion having low adhesion can be prevented from beinggenerated in the stacked-layer structure, so that film separation can bereduced. As a result, the yield in the fabrication process of thesemiconductor device can be improved. Furthermore, since there is noneed to consider the adhesion between the functional layer 135 and themetal compound layer 105 or the like, the range of choices for thematerials used for the functional layer 135 and the metal compound layer105 can be widened.

As described above, in one embodiment of the present invention,formation of an interface having low adhesion can be prevented and themetal compound layer 105 and the resin layer 123 can be separated fromeach other at desired timing. Thus, film separation during the processcan be prevented, so that the yield can be improved.

As described in this embodiment, the metal compound layer and the resinlayer that are stacked are irradiated with light, whereby the metalcompound layer and the resin layer can be separated from each other.With the use of this method, after the functional layer is formed overthe formation substrate with the metal compound layer and the resinlayer provided therebetween, the functional layer can be peeled from theformation substrate and transferred to another substrate. For example, afunctional layer which is formed over a formation substrate having highheat resistance can be transferred to a substrate having low heatresistance, and the fabrication temperature of the functional layer isnot limited by the substrate having low heat resistance. In the casewhere the functional layer is transferred to a substrate or the likewhich is more lightweight, thin, or flexible than the formationsubstrate, a variety of devices such as a semiconductor device, alight-emitting device, and a display device can be made morelightweight, thin, and flexible.

This embodiment can be combined with the other embodiments and examplesas appropriate. Moreover, in this specification, in the case where aplurality of structure examples are shown in one embodiment, thestructure examples can be combined as appropriate.

Embodiment 2

An example of the principle of separation of the metal compound layerand the resin layer from each other is described in this embodiment withreference to FIG. 8 to FIG. 11.

First, the effect that H₂O impairs adhesion between a metal compoundlayer 20 and a resin layer 23 (hereinafter referred to as an impairingeffect) is described with reference to FIG. 8 and FIG. 9.

In FIG. 8, the metal compound layer 20 is provided over a formationsubstrate 14 and the resin layer 23 is provided over the metal compoundlayer 20.

At an interface between the metal compound layer 20 and the resin layer23 and/or in the metal compound layer 20, one or more of H₂O, hydrogen(H), oxygen (O), a hydroxyl group (OH), a hydrogen radical (H*), anoxygen radical (O*), and a hydroxy radical (OH*) are present. These canbe supplied by at least one of the steps involved in formation of themetal compound layer 105 (a formation step of a metal layer, a metalnitride layer, a layer containing a metal oxide, or a metal compoundlayer, plasma treatment, heat treatment, and the like). In an example ofStep (i) in FIG. 8, H₂O, H, O, and the like are present both at theinterface between the metal compound layer 20 and the resin layer 23 andin the metal compound layer 20.

H, O, H₂O, and the like supplied to the interface between the metalcompound layer 20 and the resin layer 23 and into the metal compoundlayer 20 are sometimes separated out as H₂O at the interface by a step(e.g., heating at 350° C.) in which the resin layer 23 (e.g., apolyimide resin, an acrylic resin, or the like) is solidified (goessolid or is cured). In that case, H₂O separated out at the interfacebetween the metal compound layer 20 and the resin layer 23 might impairthe adhesion between the metal compound layer 20 and the resin layer 23.In other words, H₂O separated out at the interface between the metalcompound layer 20 and the resin layer 23 has an effect of impairingadhesion (an impairing effect). In an example of Step (ii) in FIG. 8,H₂O in the metal compound layer 20 is separated out at the interfacebetween the metal compound layer 20 and the resin layer 23. Furthermore,in the example of Step (ii) in FIG. 8, hydrogen and a hydroxyl group(OH) in the metal compound layer 20 are separated out as H₂O at theinterface between the metal compound layer 20 and the resin layer 23.

Next, a stack including the formation substrate 14, the metal compoundlayer 20, and the resin layer 23 is irradiated with light. In an exampleof Step (iii) in FIG. 9, the stack is placed with the formationsubstrate 14 positioned on the upper side. In Step (iii) in FIG. 9, thestack is moved by a transfer mechanism (not illustrated) in a directionshown by an arrow in the drawing; thus, the light irradiation isperformed from the right side to the left side in the drawing. Theinterface between the metal compound layer 20 and the resin layer 23 orthe vicinity thereof is irradiated with the light through the formationsubstrate 14. Here, an example of using linear laser light is shown. Inthe example of Step (iii) and Step (iv) in FIG. 9, a processing region27 is irradiated with a linear beam 26 through the formation substrate14. The interface between the metal compound layer 20 and the resinlayer 23 (as well as the inside of the metal compound layer 20 and theinside of the resin layer 23) is heated by the light irradiation.Furthermore, by the light irradiation, H₂O present at the interfacebetween the metal compound layer 20 and the resin layer 23 is vaporized(evaporated) instantaneously at high energy and ablation occurs.

In an example of Step (v) in FIG. 9, the stack is reversed upside down.In an example of Step (vi) in FIG. 9, the metal compound layer 20 andthe resin layer 23 are separated from each other. H₂O becomes watervapor by light irradiation to have an expanded volume. As a result, theadhesion between the metal compound layer 20 and the resin layer 23 isreduced, which allows for the separation between the metal compoundlayer 20 and the resin layer 23.

Next, a bond between the metal compound layer 20 and the resin layer 23is described with reference to FIG. 10.

In FIG. 10, the metal compound layer 20 and the resin layer 23 arestacked.

A bond is probably formed between the metal compound layer 20 and theresin layer 23. Specifically, a chemical bond such as a covalent bond,an ionic bond, or a hydrogen bond is formed between the metal compoundlayer 20 and the resin layer 23.

In an example of Step (i) in FIG. 10, a metal M of the metal compoundlayer 20 and carbon C of the resin layer 23 are bonded through oxygen O.

The stacked-layer structure of the metal compound layer 20 and the resinlayer 23 is irradiated with laser light 55 (see FIG. 10). Here, anexample of using linear laser light is shown. By relatively moving thesubstrate and a light source, scanning with the laser light 55 isperformed and the irradiation with the laser light 55 is performedacross a region where separation is desirably caused.

The light irradiation heats the interface between the metal compoundlayer 20 and the resin layer 23 (as well as the inside of the metalcompound layer 20 and the inside of the resin layer 23) and causes areaction represented by Formula (1) (see below and FIG. 10). The lightirradiation allows H₂O (water vapor) to cut the metal M-oxygen O-carbonC bond. Then, the bond between the metal compound layer 20 and the resinlayer 23 is changed into a hydrogen bond.

M-O—C+H₂O→M-OH+C—OH  (1)

In an example of Step (ii) in FIG. 10, the metal M of the metal compoundlayer 20 and the oxygen O are bonded and the carbon C of the resin layer23 and another oxygen O are bonded. The two oxygens form covalent bondswith the respective hydrogens. Furthermore, the two oxygens each form ahydrogen bond with the hydrogen bonded to the other oxygen.

A hydrogen bond is much weaker than a covalent bond and thus can beeasily cut. Furthermore, water is evaporated by energy of the lightirradiation to be water vapor. At this time, a hydrogen bond between themetal compound layer 20 and the resin layer 23 can be cut by expansionforce in some cases. Thus, the metal compound layer 20 and the resinlayer 23 can be easily separated from each other.

In an example of Step (iii) in FIG. 10, the oxygen and the hydrogen thathave been hydrogen-bonded are detached from each other and the metalcompound layer 20 and the resin layer 23 are separated from each other.The metal M of the metal compound layer 20 and the oxygen O are bondedand the carbon C of the resin layer 23 and another oxygen O are bonded.The two oxygens form covalent bonds with the respective hydrogens.

As described above, irradiating the stacked-layer structure of the metalcompound layer 20 and the resin layer 23 with light allows H₂O to changea strong bond between the metal compound layer 20 and the resin layer 23into a hydrogen bond, which is a weak bond. This can reduce the forcerequired for the separation between the metal compound layer 20 and theresin layer 23. Furthermore, the metal compound layer 20 and the resinlayer 23 can be separated from each other by expansion of H₂O due toenergy of the light irradiation.

Next, H₂O that is involved in the above impairing effect and thereaction represented by Formula (1) above is described.

H₂O is sometimes present in the metal compound layer 20, in the resinlayer 23, and at the interface between the metal compound layer 20 andthe resin layer 23, for example.

In addition, hydrogen (H), oxygen (O), a hydroxyl group (OH), a hydrogenradical (H*), an oxygen radical (O*), a hydroxy radical (OH*), and thelike present in the metal compound layer 20, in the resin layer 23, andat the interface between the metal compound layer 20 and the resin layer23, for example, are sometimes changed into H₂O by heating.

One or more of H₂O, hydrogen (H), oxygen (O), a hydroxyl group (OH), ahydrogen radical (H*), an oxygen radical (O*), and a hydroxy radical(OH*) are preferably added into the metal compound layer 20, to asurface of the metal compound layer 20 (the surface in contact with theresin layer 23), or to the interface between the metal compound layer 20and the resin layer 23.

Note that the above impairing effect and the reaction represented byFormula (1) above are sometimes caused at the same time in the peelingmethod of this embodiment. It is estimated that in that case, theadhesion between the metal compound layer 20 and the resin layer 23 canbe further reduced, or in other words, peelability between the metalcompound layer 20 and the resin layer 23 can be further increased.

It is preferable that large amounts of H₂O, hydrogen (H), oxygen (O),hydroxyl groups (OH), hydrogen radicals (H*), oxygen radicals (O*),hydroxy radicals (OH*), and the like be present in the metal compoundlayer 20, in the resin layer 23, and at the interface between the metalcompound layer 20 and the resin layer 23, for example. A larger amountof H₂O, which contributes to the reaction, promotes the reaction and canfurther reduce the force required for the separation.

For example, during the formation of the metal compound layer 20, largeamounts of H₂O, hydrogen, oxygen, hydroxyl groups, hydrogen radicals(H*), oxygen radicals (O*), hydroxy radicals (OH*), and the like arepreferably contained in the metal compound layer 20 or on the surface ofthe metal compound layer 20.

Specifically, it is preferable that one or both of the metal layer 102and the metal nitride layer 104 described in Embodiment 1 be formed andradical treatment be performed. In the radical treatment, the surface ofthe metal layer 102 or the metal nitride layer 104 is preferably exposedto an atmosphere containing at least one of an oxygen radical and ahydroxy radical. For example, plasma treatment is preferably performedin an atmosphere containing one or both of oxygen and water vapor(1420). Note that the object on which the radical treatment is performedis not limited to the metal layer and the metal nitride layer, and canbe a layer containing a metal compound such as a metal oxide or a metaloxynitride. In the radical treatment, the surface of the object ispreferably exposed to an atmosphere containing at least one kind amongan oxygen radical, a hydrogen radical, and a hydroxy radical. Forexample, plasma treatment is preferably performed in an atmospherecontaining one or more of oxygen, hydrogen, and water vapor (1420).

The radical treatment can be performed with a plasma generationapparatus or an ozone generation apparatus.

For example, oxygen plasma treatment, hydrogen plasma treatment, waterplasma treatment, ozone treatment, or the like can be performed. Oxygenplasma treatment can be performed by generating plasma in anoxygen-containing atmosphere. Hydrogen plasma treatment can be performedby generating plasma in a hydrogen-containing atmosphere. Water plasmatreatment can be performed by generating plasma in an atmospherecontaining water vapor (1420). In particular, water plasma treatment ispreferable because it makes a large amount of moisture be contained onthe surface of the metal compound layer 20 or in the metal compoundlayer 20.

Plasma treatment may be performed in an atmosphere containing two ormore kinds among oxygen, hydrogen, water (water vapor), and an inert gas(typically, argon). Examples of the plasma treatment include plasmatreatment in an atmosphere containing oxygen and hydrogen, plasmatreatment in an atmosphere containing oxygen and water, plasma treatmentin an atmosphere containing water and argon, plasma treatment in anatmosphere containing oxygen and argon, and plasma treatment in anatmosphere containing oxygen, water, and argon. The use of an argon gasfor one of gasses of the plasma treatment is favorable because the metallayer or the metal compound layer 20 can be damaged during the plasmatreatment.

Two or more kinds of plasma treatment may be performed sequentiallywithout exposure to the air. For example, water plasma treatment may beperformed after argon plasma treatment is performed.

Thus, hydrogen, oxygen, a hydrogen radical (H*), an oxygen radical (O*),a hydroxy radical (OH*), and the like can be contained on the surface ofthe metal compound layer 20 or in the metal compound layer 20 asillustrated in FIG. 11. Furthermore, in the example illustrated in FIG.11, the resin layer 23 contains hydrogen H which is bonded to carbon C(C—H) and a hydroxyl group OH which is bonded to carbon C (C—OH). Theseare probably changed into H₂O by being heated by heat treatment or lightirradiation.

As described above, the force required for separating the metal compoundlayer and the resin layer from each other can be reduced when hydrogen,oxygen, a hydrogen radical (H*), an oxygen radical (O*), a hydroxyradical (OH*), or the like is contained on the surface of the metalcompound layer or in the metal compound layer.

This embodiment can be combined with the other embodiments and examplesas appropriate.

Embodiment 3

In this embodiment, a fabrication method of a light-emitting device anda fabrication method of a display device are described with reference toFIG. 12 to FIG. 20. Furthermore, manufacturing apparatuses forfabricating these devices are described with reference to FIG. 21 andFIG. 22.

In this embodiment, the case of using Peeling method example 4 describedin Embodiment 1 is mainly described. Peeling method example 4 has afeature in that the maximum temperature applied to the second materiallayer can be lower than the maximum temperature applied to the firstmaterial layer. When the maximum temperature applied to the secondmaterial layer is lower, the second material layer can maintain a highervisible-light-transmitting property. Therefore, even when the secondmaterial layer remains on the side where light is extracted (alight-emitting surface or a display surface), the light extractionefficiency is less likely to decrease, which is preferable.

Note that portions similar to those in the peeling method described inEmbodiment 1 are not described here in detail.

[Fabrication Method Example 1]

In this Fabrication method example 1, a light-emitting device includingan organic EL element is described as an example. The light-emittingdevice can be a flexible device by using a flexible material for asubstrate.

First, a metal layer 102 a is formed over a formation substrate 101 a(FIG. 12(A)).

Next, at least part of the metal layer 102 a is oxidized. FIG. 12(B)illustrates an example in which a surface of the metal layer 102 a isirradiated with the plasma 110. Thus, a layer 103 a containing a metaloxide is formed (FIG. 12(C)).

Next, the layer 103 a containing a metal oxide is heated at the firsttemperature, whereby a metal compound layer 105 a is formed. Note thatthe layer 103 a containing a metal oxide is processed into anisland-like shape before being heated at the first temperature.Alternatively, heating at the first temperature is followed byprocessing of the metal compound layer 105 a into an island-like shape.In this manner, the island-shaped metal compound layer 105 a is formed(FIG. 12(D)).

By heating the layer 103 a containing a metal oxide at the firsttemperature, the first compound layer and the second compound layer thatis positioned closer to the substrate side than the first compound layeris are formed in the metal compound layer 105 a. Heating the layer 103 acontaining a metal oxide at a sufficiently high temperature can increasethe peelability between the layer 103 a containing a metal oxide and aresin layer 123 a.

Next, a first layer 122 a is formed over the metal compound layer 105 a(FIG. 12(E)). Then, the first layer 122 a is processed into anisland-like shape. In this embodiment, the island-shaped first layer 122a is formed to cover an end portion of the metal compound layer 105 a.

The first layer 122 a is preferably processed by a photolithographymethod. Pre-baking treatment is performed after formation of the firstlayer 122 a, and then light exposure is performed using a photomask.Then, development treatment is performed, whereby an unnecessary portioncan be removed.

Note that the first layer 122 a (which is to be the resin layer 123 alater) is not necessarily in the form of a single island and may be inthe form of a plurality of islands or a shape having an opening, forexample. In addition, an unevenness shape may be formed on the surfaceof the first layer 122 a (which is to be the resin layer 123 a later) bya light exposure technique using a half-tone mask or a gray-tone mask, amultiple light exposure technique, or the like.

The resin layer 123 a with a desired shape can be formed in such amanner that a mask such as a resist mask or a hard mask is formed overthe first layer 122 a or the resin layer 123 a and etching is performed.This method is particularly suitable for the case of using anon-photosensitive material.

For example, an inorganic film is formed over the resin layer 123 a, anda resist mask is formed over the inorganic film. After the inorganicfilm is etched with the use of the resist mask, the resin layer 123 acan be etched using the inorganic film as a hard mask.

As an inorganic film that can be used as the hard mask, a variety ofinorganic insulating films, metal films and alloy films that can be usedfor a conductive layer, and the like can be given.

It is preferable that the mask with an extremely small thickness can beformed and the mask can be removed concurrently with the etching, inwhich case a step of removing the mask can be eliminated.

Next, heat treatment is performed at the second temperature in a statewhere the metal compound layer 105 a and the first layer 122 a arestacked. By heating the island-shaped first layer 122 a, the first layer122 a is cured and the resin layer 123 a having an island-like shape isformed (FIG. 12(F1)). The second temperature can be lower than the firsttemperature. Thus, the resin layer 123 a with a highvisible-light-transmitting property can be formed.

Structure examples of the metal compound layer 105 a are illustrated inFIGS. 12(F2) and 12(F3). The metal compound layer 105 a illustrated inFIG. 12(F2) has a three-layer structure, and the metal compound layer105 a illustrated in FIG. 12(F3) has a two-layer structure. The metalcompound layer 105 a illustrated in FIGS. 12(F2) and 12(F3) includes afirst compound layer 111 a in contact with the resin layer 123 a and asecond compound layer 112 a that is positioned closer to the formationsubstrate 101 a side than the first compound layer 111 a is. Asillustrated in FIG. 12(F2), the metal compound layer 105 a can furtherinclude a third compound layer 113 a that is positioned closer to theformation substrate 101 a side than the second compound layer 112 a is.

Next, components of the light-emitting device are sequentially formed.Specifically, an insulating layer 167 is formed over the resin layer 123a, a conductive layer 171, an auxiliary wiring 172, a conductive layer173, an insulating layer 178, and a light-emitting element 160 areformed over the insulating layer 167, and an insulating layer 165 isformed over the light-emitting element 160. Then, a substrate 175 isbonded with the use of an adhesive layer 174 (FIG. 13(A)).

The temperature applied to the resin layer 123 a is preferably lowerthan or equal to the second temperature in the fabrication process ofthe components of the light-emitting device. Accordingly, the highvisible-light-transmitting property of the resin layer 123 a can bemaintained and the light extraction efficiency of the light-emittingdevice can be increased. Furthermore, a gas released from the resinlayer 123 a can be reduced, and the reliability of the light-emittingdevice can be increased.

The insulating layer 167 can be used as a barrier layer that preventsdiffusion of impurities contained in the resin layer 123 a to thelight-emitting element 160 formed later. For example, the insulatinglayer 167 preferably prevents moisture and the like contained in theresin layer 123 a from diffusing to the light-emitting element 160 whenthe resin layer 123 a is heated. Thus, the insulating layer 167preferably has a high barrier property.

As the insulating layer 167, for example, an inorganic insulating filmsuch as a silicon nitride film, a silicon oxynitride film, a siliconoxide film, a silicon nitride oxide film, an aluminum oxide film, or analuminum nitride film can be used. Moreover, a hafnium oxide film, anyttrium oxide film, a zirconium oxide film, a gallium oxide film, atantalum oxide film, a magnesium oxide film, a lanthanum oxide film, acerium oxide film, a neodymium oxide film, or the like may be used.Furthermore, a stack of two or more of the above insulating films mayalso be used. It is particularly preferable that a silicon nitride filmbe formed over the resin layer 123 a and a silicon oxide film be formedover the silicon nitride film.

An inorganic insulating film is preferably formed at high temperaturesbecause the film can have higher density and a higher barrier propertyas the film formation temperature is higher.

The substrate temperature during the formation of the insulating layer167 is preferably higher than or equal to room temperature (25° C.) andlower than or equal to 350° C., further preferably higher than or equalto 100° C. and lower than or equal to 300° C.

The light-emitting element 160 may be of top-emission type,bottom-emission type, or dual-emission type. A conductive film thattransmits visible light is used for the electrode on the side wherelight is extracted. Moreover, a conductive film that reflects visiblelight is preferably used for the electrode on the side where light isnot extracted.

The light-emitting element 160 illustrated in FIG. 13(A) is abottom-emission light-emitting element. A first electrode 161 is anelectrode on the side where light is extracted, and transmits visiblelight. A second electrode 163 is an electrode on the side where light isnot extracted, and reflects visible light.

Either a low molecular compound or a high molecular compound can be usedfor an EL layer 162, and an inorganic compound may also be included.

The first electrode 161 and the second electrode 163 can each be formedby an evaporation method, a sputtering method, or the like.

The conductive layer 171 and the conductive layer 173 each function asan external connection electrode. The conductive layer 171 iselectrically connected to the first electrode 161. The conductive layer171 is electrically insulated from the second electrode 163 by theinsulating layer 178. The conductive layer 173 is electrically connectedto the second electrode 163. The conductive layer 173 is electricallyinsulated from the first electrode 161 by the insulating layer 178.

The conductive film that transmits visible light has a higherresistivity than a metal film or the like in some cases. For thisreason, the auxiliary wiring 172 in contact with the first electrode 161is preferably provided. The auxiliary wiring 172 can be formed using thesame material and the same process as those of the conductive layer 171and the conductive layer 173. A metal material having a low resistivityis preferably used for the auxiliary wiring 172.

The insulating layer 165 functions as a protective layer that preventsdiffusion of impurities such as water to the light-emitting element 160.The light-emitting element 160 is sealed with the insulating layer 165.After the second electrode 163 is formed, the insulating layer 165 ispreferably formed without exposure to the air.

The insulating layer 165 preferably includes an inorganic insulatingfilm with a high barrier property that can be used as the insulatinglayer 167. Furthermore, a stack of an inorganic insulating film and anorganic insulating film may also be used.

The insulating layer 165 can be formed by an ALD method, a sputteringmethod, or the like. An ALD method and a sputtering method arepreferable because low-temperature film formation is possible. Using anALD method is preferable because the coverage with the insulating layer165 becomes favorable.

For the adhesive layer 174, the description of the adhesive layer 145can be referred to.

For the substrate 175, the description of the substrate 146 can bereferred to.

Next, the irradiation with the laser light 155 is performed (FIG.13(B)). In the laser apparatus, the stack is placed with the formationsubstrate 101 a being on the upper side. The stack is irradiated withthe laser light 155 from the upper side of the stack (the formationsubstrate 101 a).

Next, a separation trigger is formed in the resin layer 123 a (FIG.13(C)). For example, a sharp instrument 153, e.g., a knife, is insertedfrom the substrate 175 side into a portion located inward from an endportion of the resin layer 123 a to make a cut in a frame-like shape.This is suitable for the case where a resin is used for the substrate175. Alternatively, the resin layer 123 a may be irradiated with laserlight in a frame-like shape.

In this Fabrication method example 1, the metal compound layer 105 a andthe resin layer 123 a are provided in an island-like shape. The portionwhere these layers are not provided over the formation substrate 101 a(the portion where the substrate 101 a and the insulating layer 167 arein contact with each other) has high adhesion even after the irradiationwith the laser light 155 is performed. Therefore, unintentional peelingof the resin layer 123 a from the metal compound layer 105 a can beinhibited. In addition, the formation of the separation trigger enablesthe metal compound layer 105 a and the resin layer 123 a to be separatedfrom each other at desired timing. Accordingly, the timing of theseparation can be controlled and the force required for the separationis small. This can increase the yield of the separation process and thatof the fabrication process of the light-emitting device.

Then, the metal compound layer 105 a and the resin layer 123 a areseparated from each other (FIG. 14(A)). As illustrated in FIG. 14(A),separation occurs at an interface between the metal compound layer 105 aand the resin layer 123 a.

After that, a substrate 177 is bonded to the exposed resin layer 123 awith an adhesive layer 176 (FIG. 14(B)). As illustrated in FIG. 14(B),an opening reaching the conductive layer 171 and an opening reaching theconductive layer 173 are formed in the substrate 175 and the adhesivelayer 174, so that the conductive layer 171 and the conductive layer 173are exposed.

Note that it is also possible to remove the resin layer 123 a and bondthe substrate 177 to the insulating layer 167 with the use of theadhesive layer 176 as illustrated in FIG. 14(C). For example, the resinlayer 123 a can be removed by ashing using oxygen plasma. By removingthe resin layer 123 a, the thickness of the light-emitting device can bereduced and the flexibility can be increased.

As described above, in this Fabrication method example 1, the resinlayer 123 a can have a high visible-light-transmitting property.Therefore, even when the resin layer 123 a remains on the side where thelight emitted by the light-emitting element 160 is extracted, the lightextraction efficiency is less likely to decrease. Therefore, even whenthe resin layer 123 a is not removed, a light-emitting device with highlight extraction efficiency can be fabricated. Therefore, thefabrication process of the light-emitting device can be simplified.

In this embodiment, the resin layer 123 a does not need to be providedto have a large thickness. The thickness of the resin layer 123 a canbe, for example, greater than or equal to 0.1 μm and less than or equalto 5 μm, or even greater than or equal to 0.1 μm and less than or equalto 3 μm. Therefore, a highly flexible light-emitting device can befabricated even when the resin layer 123 a is not removed. This makes itpossible to omit the step of removing the resin layer 123 a, which isalso preferable.

The adhesive layer 176 and the substrate 177 preferably have a hightransmitting property with respect to the light emitted by thelight-emitting element 160.

The substrate 177 can function as a supporting substrate of thelight-emitting device. A film is preferably used as the substrate 177,and a resin film is particularly preferably used. In that case, thelight-emitting device can be reduced in weight and thickness.Furthermore, the light-emitting device using a film substrate is lesslikely to be broken than that in the case of using glass, a metal, orthe like. In addition, the light-emitting device can have higherflexibility.

For the adhesive layer 176, the material that can be used for theadhesive layer 174 can be used. The material that can be used for thesubstrate 175 can be used for the substrate 177.

As described above, in this embodiment, the formation substrate can bepeeled with the use of a resin layer having a highvisible-light-transmitting property. Therefore, even when the resinlayer is not removed, a light-emitting device with high light extractionefficiency can be fabricated. Furthermore, since a thin resin layer canbe used, a highly flexible light-emitting device can be fabricated.

[Fabrication Method Example 2]

In this Fabrication method example 2, a display device that includes atransistor and an organic EL element (also referred to as an activematrix organic EL display device) will be described as an example.Furthermore, in this Fabrication method example 2, a display device thatincludes a transistor, an organic EL element, and a sensor element (alsoreferred to as an input/output device or a touch panel; hereinafterreferred to as a touch panel) will also be described. These displaydevices can each be a flexible device by using a flexible material for asubstrate.

In this Fabrication method example 2, components on one substrate sideof the display device are formed over the formation substrate 101 a, andcomponents on the other substrate side of the display device are formedover a formation substrate 101 b. These components are formed over theformation substrate with a metal compound layer and a resin layerprovided therebetween. Thus, these components can be peeled from theformation substrate and transferred to a flexible substrate.

First, as in Fabrication method example 1, the steps of FIGS. 12(A) to12(F) are performed to form a stack of the metal compound layer 105 aand the resin layer 123 a over the formation substrate 101 a.

Next, the components on one substrate side of the display device aresequentially formed. Since the resin layer 123 a is a layer which has ahigh visible-light-transmitting property, it is preferable thatcomponents positioned on the display surface side be formed over theresin layer 123 a. Specifically, an insulating layer 191 is formed overthe resin layer 123 a, and a coloring layer 197 and a light-blockinglayer 198 are formed over the insulating layer 191 (FIG. 15(A)). Inaddition, an overcoat or the like may be formed.

In the fabrication process of the components of the display device, thetemperature applied to the resin layer 123 a is preferably lower than orequal to the second temperature. Accordingly, the resin layer 123 a canmaintain a high visible-light-transmitting property, which can increasethe light extraction efficiency of the display device. Furthermore, agas released from the resin layer 123 a can be inhibited, and thereliability of the display device can be increased.

For the insulating layer 191, the description of the insulating layer167 can be referred to.

A color filter or the like can be used as the coloring layer 197. Thecoloring layer 197 is placed to overlap with a display region of thelight-emitting element 160.

A black matrix or the like can be used as the light-blocking layer 198.The light-blocking layer 198 is placed to overlap with an insulatinglayer 209.

In the case where a touch panel is formed, a sensor element is formedover the insulating layer 191, and the coloring layer 197 and thelight-blocking layer 198 are formed over the sensor element (FIG.15(B)).

Any of a variety of sensors that can sense the proximity or touch of asensing target such as a finger can be used as a touch sensor.

As the touch sensor, for example, a capacitive touch sensor can be used.Examples of the capacitive type include a surface capacitive type and aprojected capacitive type. Examples of the projected capacitive typeinclude a self-capacitive type and a mutual-capacitive type. The use ofa mutual-capacitive touch sensor is preferred because multiple pointscan be sensed simultaneously.

The sensor element illustrated in FIG. 15(B) includes a conductive layer181 and conductive layers 182. An insulating layer 184 is provided overthe conductive layer 181 and the conductive layers 182, and a conductivelayer 183 is provided over the insulating layer 184. The conductivelayer 183 electrically connects the two conductive layers 182 betweenwhich one conductive layer 181 is positioned. An insulating layer 185 isprovided over the conductive layer 183, and the coloring layer 197 andthe light-blocking layer 198 are provided over the insulating layer 185.Since the conductive layer 181 and the conductive layers 182 overlapwith the display region of the display device, the conductive layer 181and the conductive layers 182 are formed using a material having a hightransmitting property with respect to visible light.

As illustrated in FIG. 16(A), a stack of a metal compound layer 105 band a resin layer 123 b is formed over the formation substrate 101 b.The metal compound layer 105 b and the resin layer 123 b can be formedby any one of or a combination of the methods described in Embodiment 1as examples. For example, fabrication methods similar to those of themetal compound layer 105 a and the resin layer 123 a may be employed.

As described in Peeling method examples 1 to 3 in Embodiment 1, forexample, the metal compound layer 105 b and the resin layer 123 b may beformed by performing heat treatment once. The resin layer 123 b is notpositioned on the light extraction side of the display device and thusmay have a low visible-light-transmitting property.

For example, it is preferable that an acrylic resin be used for theresin layer 123 a and a polyimide resin be used for the resin layer 123b. An acrylic resin has a higher visible-light-transmitting propertythan a polyimide resin and thus is suitable as a material for the resinlayer 123 a positioned on the light extraction side. A polyimide resinhas higher heat resistance than an acrylic resin; thus, a transistor andthe like can be formed over a polyimide resin at a relatively hightemperature. Thus, a highly reliable transistor can be fabricated, whichis preferable.

Next, the components on the other substrate side of the display deviceare sequentially formed. Specifically, an insulating layer 141 is formedover the resin layer 123 b, and a transistor 210, an insulating layer208, the insulating layer 209, and the light-emitting element 160 areformed over the insulating layer 141 (FIG. 16(A)).

For the insulating layer 141, the description of the insulating layer167 can be referred to.

Here, transistors that can be used in the display device are described.

There is no particular limitation on the structure of the transistorincluded in the display device. For example, a planar transistor may beused, a staggered transistor may be used, or an inverted staggeredtransistor may be used. In addition, a top-gate transistor or abottom-gate transistor may be used. Alternatively, gate electrodes maybe provided above and below a channel.

FIG. 16(A) illustrates the case where a top-gate transistor whosesemiconductor layer includes a metal oxide is formed as the transistor210. A metal oxide can function as an oxide semiconductor.

An oxide semiconductor is preferably used as the semiconductor of thetransistor. A semiconductor material having a wider bandgap and a lowercarrier density than silicon is preferably used because the off-statecurrent of the transistor can be reduced.

The transistor 210 includes a conductive layer 201, an insulating layer202, a conductive layer 203 a, a conductive layer 203 b, a semiconductorlayer, a conductive layer 205, an insulating layer 206, and aninsulating layer 207. The conductive layer 201 functions as a gate. Theconductive layer 205 functions as a back gate. The insulating layer 202and the insulating layer 206 function as gate insulating layers. Thesemiconductor layer includes a channel region 204 a and a pair oflow-resistance regions 204 b. The channel region 204 a overlaps with theconductive layer 205 with the insulating layer 206 positionedtherebetween. The channel region 204 a overlaps with the conductivelayer 201 with the insulating layer 202 positioned therebetween. Theconductive layer 203 a is electrically connected to one of the pair oflow-resistance regions 204 b through an opening in the insulating layer207. Similarly, the conductive layer 203 b is electrically connected tothe other of the pair of low-resistance regions 204 b. Any of a varietyof inorganic insulating films can be used for the insulating layer 202,the insulating layer 206, and the insulating layer 207. Specifically, anoxide insulating film is suitable for the insulating films which areincluded in the insulating layer 202 and the insulating layer 206 andare in contact with the channel region 204 a, and a nitride insulatingfilm is suitable for the insulating layer 207.

The structure in which the semiconductor layer where a channel is formedis provided between two gates is used for the transistor 210. The twogates are preferably connected to each other and supplied with the samesignal to operate the transistor. Such a transistor can have higherfield-effect mobility and thus have a higher on-state current than othertransistors. Consequently, a circuit capable of high-speed operation canbe fabricated. Furthermore, the area occupied by a circuit portion canbe reduced. The use of the transistor having a high on-state current canreduce signal delay in wirings and can suppress display unevenness evenif the number of wirings is increased when a display device is increasedin size or resolution. Alternatively, by supplying a potential forcontrolling the threshold voltage to one of the two gates and apotential for driving to the other, the threshold voltage of thetransistor can be controlled.

For the conductive layers included in the display device, a single-layerstructure or a stacked-layer structure of any of metals such asaluminum, titanium, chromium, nickel, copper, yttrium, zirconium,molybdenum, silver, tantalum, and tungsten or an alloy containing any ofthese metals as its main component can be used. Alternatively, alight-transmitting conductive material such as indium oxide, ITO, indiumoxide containing tungsten, indium zinc oxide containing tungsten, indiumoxide containing titanium, ITO containing titanium, indium zinc oxide,ZnO, ZnO containing gallium, or ITO containing silicon may be used.Furthermore, a semiconductor such as an oxide semiconductor orpolycrystalline silicon whose resistance is lowered by containing animpurity element, for example, or silicide such as nickel silicide maybe used. Furthermore, a film containing graphene can also be used. Thefilm containing graphene can be formed, for example, by reducing a filmcontaining graphene oxide. Furthermore, a semiconductor such as an oxidesemiconductor containing an impurity element may also be used.Alternatively, the conductive layers may be formed using a conductivepaste of silver, carbon, copper, or the like or a conductive polymersuch as polythiophene. A conductive paste is preferable because it isinexpensive. A conductive polymer is preferable because it is easilyapplied.

A metal oxide film that functions as a semiconductor layer can be formedusing either or both of an inert gas and an oxygen gas. Note that thereis no particular limitation on the flow rate ratio of oxygen (thepartial pressure of oxygen) at the time of forming the metal oxide film.However, to obtain a transistor having high field-effect mobility, theflow rate ratio of oxygen (the partial pressure of oxygen) at the timeof forming the metal oxide film is preferably higher than or equal to 0%and lower than or equal to 30%, further preferably higher than or equalto 5% and lower than or equal to 30%, still further preferably higherthan or equal to 7% and lower than or equal to 15%.

The metal oxide preferably contains at least indium or zinc. Inparticular, the metal oxide preferably contains indium and zinc. Themetal oxide will be described in detail in Embodiment 4.

The energy gap of the metal oxide is preferably 2 eV or more, furtherpreferably 2.5 eV or more, still further preferably 3 eV or more. Withthe use of a metal oxide having such a wide energy gap, the off-statecurrent of the transistor can be reduced.

The metal oxide film can be formed by a sputtering method.Alternatively, a PLD method, a PECVD method, a thermal CVD method, anALD method, a vacuum evaporation method, or the like may be used.

FIGS. 16(B) to 16(D) illustrate other structure examples of transistors.

A transistor 220 illustrated in FIG. 16(B) is a bottom-gate transistorincluding a metal oxide in a semiconductor layer 204.

The transistor 220 includes the conductive layer 201, the insulatinglayer 202, the conductive layer 203 a, the conductive layer 203 b, andthe semiconductor layer 204. The conductive layer 201 functions as agate. The insulating layer 202 functions as a gate insulating layer. Thesemiconductor layer 204 overlaps with the conductive layer 201 with theinsulating layer 202 therebetween. The conductive layer 203 a and theconductive layer 203 b are each electrically connected to thesemiconductor layer 204. The transistor 220 is preferably covered withan insulating layer 211 and an insulating layer 212. Any of a variety ofinorganic insulating films can be used for the insulating layer 211 andthe insulating layer 212. Specifically, an oxide insulating film issuitable for the insulating layer 211, and a nitride insulating film issuitable for the insulating layer 212.

A transistor 230 illustrated in FIG. 16(C) is a top-gate transistorincluding LTPS in its semiconductor layer.

The transistor 230 includes the conductive layer 201, the insulatinglayer 202, the conductive layer 203 a, the conductive layer 203 b, asemiconductor layer, and an insulating layer 213. The conductive layer201 functions as a gate. The insulating layer 202 functions as a gateinsulating layer. The semiconductor layer includes a channel region 214a and a pair of low-resistance regions 214 b. The semiconductor layermay further include a lightly doped drain (LDD) region. FIG. 16(C) showsan example in which an LDD region 214 c is provided between the channelregion 214 a and the low-resistance region 214 b. The channel region 214a overlaps with the conductive layer 201 with the insulating layer 202provided therebetween. The conductive layer 203 a is electricallyconnected to one of the pair of low-resistance regions 214 b through anopening provided in the insulating layer 202 and the insulating layer213. In a similar manner, the conductive layer 203 b is electricallyconnected to the other of the pair of low-resistance regions 214 b. Anyof a variety of inorganic insulating films can be used for theinsulating layer 213. Specifically, a nitride insulating film issuitable for the insulating layer 213.

A transistor 240 illustrated in FIG. 16(D) shows a bottom-gatetransistor containing hydrogenated amorphous silicon in a semiconductorlayer 224.

The transistor 240 includes the conductive layer 201, the insulatinglayer 202, the conductive layer 203 a, the conductive layer 203 b, animpurity semiconductor layer 225, and the semiconductor layer 224. Theconductive layer 201 functions as a gate. The insulating layer 202functions as a gate insulating layer. The semiconductor layer 224overlaps with the conductive layer 201 with the insulating layer 202therebetween. The conductive layer 203 a and the conductive layer 203 bare electrically connected to the semiconductor layer 224 through theimpurity semiconductor layer 225. The transistor 240 is preferablycovered with an insulating layer 226. Any of a variety of inorganicinsulating films can be used for the insulating layer 226. Specifically,a nitride insulating film is suitable for the insulating layer 226.

Next, the components formed over the transistor 210 will be described.

The insulating layer 208 is formed over the transistor 210. An openingreaching the conductive layer 203 b is formed in the insulating layer208. The insulating layer 208 is a layer having a surface where thelight-emitting element 160 formed later is to be formed, and thuspreferably functions as a planarization layer. Any of a variety oforganic insulating films and a variety of inorganic insulating films canbe used for the insulating layer 208.

The light-emitting element 160 illustrated in FIG. 16(A) is atop-emission light-emitting element. The first electrode 161 is anelectrode on the side where light is not extracted, and reflects visiblelight. The second electrode 163 is an electrode on the side where lightis extracted, and transmits visible light. An end portion of the firstelectrode 161 is covered with the insulating layer 209. Any of a varietyof organic insulating films and a variety of inorganic insulating filmscan be used for the insulating layer 209. The first electrode 161 iselectrically connected to the conductive layer 203 b through an openingprovided in the insulating layer 208. Thus, the transistor 210 and thelight-emitting element 160 can be electrically connected to each other.

The EL layer 162 can be formed by an evaporation method, a coatingmethod, a printing method, a discharge method, or the like. In the casewhere the EL layer 162 is separately formed for each individual pixel,it can be formed by an evaporation method using a shadow mask such as ametal mask, an ink-jet method, or the like. In the case of notseparately forming the EL layer 162 for each individual pixel, anevaporation method not using a metal mask can be used.

Then, with the use of an adhesive layer 195, the surface of theformation substrate 101 b where the transistor 210 and the like areformed and the surface of the formation substrate 101 a where thecoloring layer 197 and the like are formed are bonded to each other(FIG. 17(A)).

Next, irradiation with the laser light 155 is performed (FIG. 17(B)).

Either the formation substrate 101 a or the formation substrate 101 bmay be separated first. In this example, separation of the formationsubstrate 101 a precedes that of the formation substrate 101 b.

The interface between the metal compound layer 105 a and the resin layer123 a or the vicinity thereof is preferably irradiated with the laserlight 155 through the formation substrate 101 a. Furthermore, the insideof the metal compound layer 105 a may be irradiated with the laser light155 or the inside of the resin layer 123 a may be irradiated with thelaser light 155.

Most of the laser light 155 is absorbed by three layers, i.e., theformation substrate, the metal compound layer, and the resin layer, onthe side where the irradiation with the laser light 155 is performed.For that reason, with single irradiation with the laser light 155, onlyone of adhesion between the metal compound layer 105 a and the resinlayer 123 a and adhesion between the metal compound layer 105 b and theresin layer 123 b can be lowered. The timing of separation can bedifferent between the formation substrate 101 a and the formationsubstrate 101 b; therefore, the formation substrate 101 a and theformation substrate 101 b can be separated in different steps. This canincrease the yield of the separation process and that of the fabricationprocess of the display device.

Then, the formation substrate 101 a and the resin layer 123 a areseparated from each other (FIG. 18(A)). Note that a separation triggermay be formed.

Next, the substrate 175 and the resin layer 123 a that is exposed bybeing separated from the formation substrate 101 a are bonded to eachother using the adhesive layer 174 (FIG. 18(B)).

As described above, in this Fabrication method example 2, the resinlayer 123 a can have a high visible-light-transmitting property.Accordingly, light extraction efficiency is less likely to decrease evenwhen the resin layer 123 a remains on the side where the light emittedby the light-emitting element 160 is extracted. Therefore, even when theresin layer 123 a is not removed, a light-emitting device with highlight extraction efficiency can be fabricated. Therefore, thefabrication process of the light-emitting device can be simplified. Notethat the resin layer 123 a may be removed and the insulating layer 191and the substrate 175 may be adhered to each other.

The adhesive layer 174 and the substrate 175 preferably have a hightransmitting property with respect to the light emitted by thelight-emitting element 160.

Next, the irradiation with the laser light 155 is performed (FIG.19(A)). An interface between the metal compound layer 105 b and theresin layer 123 b or the vicinity thereof is preferably irradiated withthe laser light 155 through the formation substrate 101 b. Furthermore,the inside of the metal compound layer 105 b may be irradiated with thelaser light 155 or the inside of the resin layer 123 b may be irradiatedwith the laser light 155.

Next, a separation trigger is formed in the resin layer 123 b (FIG.19(B)). In FIG. 19(B), the sharp instrument 153, e.g., a knife, isinserted from the substrate 175 side into a portion located inward froman end portion of the resin layer 123 b to make a cut in a frame-likeshape.

The formation of the separation trigger enables the formation substrate101 b and the resin layer 123 b to be separated from each other atdesired timing. Accordingly, the timing of the separation can becontrolled and the force required for the separation is small. This canincrease the yield of the separation process and that of the fabricationprocess of the display device.

Then, the formation substrate 101 b and the resin layer 123 b areseparated from each other (FIG. 20(A)).

Next, the substrate 177 and the resin layer 123 b that is exposed bybeing separated from the formation substrate 101 b are bonded to eachother using the adhesive layer 176 (FIG. 20(B)).

The resin layer 123 b, the adhesive layer 176, and the substrate 177 arepositioned on the side opposite to the side where the light emitted bythe light-emitting element 160 is extracted; thus, theirvisible-light-transmitting properties do not matter.

In Fabrication method example 2, the peeling method of one embodiment ofthe present invention is conducted twice to fabricate the displaydevice. In one embodiment of the present invention, each of thefunctional elements and the like included in the display device isformed over the formation substrate; thus, even in the case where ahigh-resolution display device is fabricated, high alignment accuracy ofa flexible substrate is not required. It is thus easy to attach theflexible substrate.

As described above, in this embodiment, the formation substrate can bepeeled with the use of a resin layer having a highvisible-light-transmitting property. Therefore, a display device withhigh light extraction efficiency can be fabricated without removal ofthe resin layer. Furthermore, a thin resin layer can be used, whichenables fabricating a highly flexible display device.

Note that when the surfaces of the resin layers 123 a and 123 b of thelight-emitting device or the display device described in this embodimentare analyzed, the metal contained in the metal compound layers 105 a and105 b is sometimes detected.

[Example of Stack Fabrication Apparatus]

Next, an example of a stack fabrication apparatus will be described withreference to FIG. 21. With the stack fabrication apparatus illustratedin FIG. 21, a functional layer can be peeled from a formation substrateby the peeling method of one embodiment of the present invention andtransferred to another substrate. With the use of the stack fabricationapparatus illustrated in FIG. 21, a stack such as a semiconductor deviceor a display device can be fabricated.

The stack fabrication apparatus illustrated in FIG. 21 includes a laserirradiation unit 610, a substrate reversing unit 630, a plurality oftransfer rollers (e.g., transfer rollers 643, 644, 645, and 646), a tapereel 602, a wind-up reel 683, a direction changing roller 604, and apress roller 606.

A stack 56 that can be treated with the stack fabrication apparatusillustrated in FIG. 21 has, for example, a structure in which a member56 a to be peeled and a support 56 b are stacked. In the stack 56,peeling occurs between the member 56 a to be peeled and the support 56b. The member 56 a to be peeled includes a resin layer and the support56 b includes a formation substrate, for example.

The stack fabrication apparatus illustrated in FIG. 21 attaches asupport 601 to the stack 56 and pulls the support 601, so that themember 56 a to be peeled is peeled from the stack 56. Since the stack 56can be automatically divided with the use of the support 601, theprocessing time can be shortened and the manufacturing yield of productscan be improved.

The member 56 a to be peeled that is separated from the support 56 b isbonded to a support 671 with an adhesive. As a result, a stack 59 inwhich the support 601, the member 56 a to be peeled, and the support 671are stacked in this order can be fabricated.

The plurality of transfer rollers can transfer the stack 56. Thetransfer mechanism that transfers the stack 56 is not limited to atransfer roller and may be a conveyor belt, a transfer robot, or thelike. Furthermore, the stack 56 may be placed over a stage over thetransfer mechanism.

The transfer roller 643, the transfer roller 644, the transfer roller645, and the transfer roller 646, each of which is one of the pluralityof transfer rollers that are lined up, are provided at predeterminedintervals and rotationally driven in the direction in which the stack56, the member 56 a to be peeled, or the support 56 b is sent (theclockwise direction as indicated by solid arrows). The plurality oflined-up transfer rollers are each rotationally driven by a drivingportion (e.g., a motor), which is not illustrated.

The laser irradiation unit 610 is a unit for irradiating the stack 56with laser light. As a laser, for example, an excimer laser that emitsultraviolet light with a wavelength of 308 nm can be used. Furthermore,a high-pressure mercury lamp, a UV-LED, or the like may be used.

As illustrated in FIG. 21, the stack 56 is transferred to the laserirradiation unit 610 with the support 56 b positioned on the upper side.

The excimer laser is a pulsed laser with high output, which can shape abeam into a linear form with an optical system. The substrate is movedat an irradiation position of a linear laser light beam, so that thewhole or necessary portion of the substrate can be irradiated with laserlight. Note that when the length of a linear beam is longer than orequal to one side of the substrate used, moving the substrate only inone direction enables the whole substrate to be irradiated with laserlight. The oscillation frequency of the pulsed laser is preferablygreater than or equal to 1 Hz and less than or equal to 300 Hz, furtherpreferably around 60 Hz.

As an excimer laser apparatus, besides an apparatus on which one laseroscillator is mounted, an apparatus on which two or more laseroscillators are mounted can also be used. In the apparatus on which aplurality of laser oscillators are mounted, laser light that is outputin synchronization from the laser oscillators is synthesized(superimposed) with an optical system, so that laser light with highenergy density can be obtained. Thus, in the application according tothis embodiment, a glass substrate whose size is larger than or equal tothe 3.5th generation (600 mm×720 mm), larger than or equal to the 6thgeneration (1500 mm×1850 mm), larger than or equal to the 7th generation(1870 mm×2200 mm), or larger than or equal to the 8th generation (2160mm×2460 mm) can also be treated. Furthermore, in the apparatus on whicha plurality of laser oscillators are mounted, the output variations oflaser light emitted from the laser oscillators compensate for eachother, so that a variation in intensity per pulse is reduced, andhigh-yield treatment can be performed. Note that instead of a pluralityof oscillators, a plurality of excimer laser apparatuses may be used.

FIG. 22(A) illustrates an example of the laser irradiation unit 610using an excimer laser. Laser light 610 a and laser light 610 b emittedfrom an excimer laser apparatus 660 having two laser oscillators aresynthesized by an optical system 635. Moreover, laser light 610 c thatis extended horizontally by the optical system 635 is incident on a lens680 via a mirror 650. Laser light 610 d transmitted through the lens 680is reduced compared with the laser light 610 c. At this time, aprocessing region 640 included in the stack 56 is irradiated with thelaser light 610 d through the support 56 b (e.g., a glass substrate).Hereinafter, part of the laser light 610 d with which the processingregion 640 is irradiated is referred to as a linear beam 610 e.

Note that although the example including two laser oscillators isdescribed here, the structure including one laser oscillator may beused, in which case the apparatus can be simplified. Furthermore, thestructure including three or more laser oscillators may be used, inwhich case the intensity of the linear beam 610 e can be increased.

By moving the stack 56 by the transfer roller 644 in a directionindicated by an arrow in the drawing, the processing region 640 can beirradiated with the linear beam 610 e.

The irradiation with the linear beam 610 e is performed while the stack56 is transferred by the transfer roller 644 at a certain speed asillustrated in FIG. 22(A); thus, the processing time can be shortened.Note that the stack 56 may be placed on a stage that is movable at leastin one direction, and the irradiation with the linear beam 610 e may beperformed while the stage is moved. Note that in the case of using astage, the stage is preferably movable in a lateral direction withrespect to a travelling direction and a height direction and ispreferably capable of adjusting the position or the depth of the focusof the linear beam 610 e. Note that although FIG. 22(A) illustrates anexample where the irradiation with the linear beam 610 e is performed bymoving the stack 56, one embodiment of the present invention is notlimited thereto. For example, the stack 56 may be irradiated with thelinear beam 610 e by fixing the stack 56 and moving the excimer laserapparatus 660 or the like.

In the example illustrated in FIG. 22(A), the processing region 640 thatis irradiated with the linear beam 610 e is located inward from an endportion of the stack 56. Thus, a region outside the processing region640 maintains a strong adhesion state, which can prevent peeling duringtransfer. Note that the width of the linear beam 610 e may be the sameas that of the stack 56 or larger than that of the stack 56. In thatcase, the whole stack 56 can be irradiated with the linear beam 610 e.

FIG. 22(B) illustrates a state where the processing region 640 of thestack 56 is irradiated with the linear beam 610 e. The stack 56 includesa formation substrate 58, a first layer 57 a, and a second layer 57 b.Here, a portion including the formation substrate 58 and the secondlayer 57 b corresponds to the support 56 b, and a portion including thefirst layer 57 a corresponds to the member 56 a to be peeled.

For example, the first layer 57 a corresponds to the resin layer 123 andthe second layer 57 b corresponds to the metal compound layer 105.

It is preferable that the laser light 610 d pass through the formationsubstrate 58 and an interface between the first layer 57 a and thesecond layer 57 b or the vicinity thereof be irradiated with the linearbeam 610 e. It is particularly preferable that the focus of the linearbeam 610 e be positioned at the interface between the first layer 57 aand the second layer 57 b or the vicinity thereof.

Furthermore, when the focus of the linear beam 610 e is positioned atthe interface between the first layer 57 a and the second layer 57 b,water which might exist at the interface between the first layer 57 aand the second layer 57 b is vaporized and the volume of the waterrapidly increases in some cases. In that case, a peeling phenomenon isassumed to occur at the interface between the first layer 57 a and thesecond layer 57 b or the vicinity thereof owing to the increase in thevolume of the water.

Note that there is a technique of crystallizing an amorphous siliconfilm by irradiation of the amorphous silicon film with laser light. Inthe case of the technique, the laser light is focused on the inside ofthe amorphous silicon film. However, in one embodiment of the presentinvention, as illustrated in FIG. 22(B), the focus of the laser light(here, the linear beam 610 e) is at the interface between the firstlayer 57 a and the second layer 57 b or the vicinity thereof. In thismanner, one embodiment of the present invention is different from thetechnique of crystallizing an amorphous silicon film in the focusposition of laser light.

Furthermore, in the case where the depth of the focus of the linear beam610 e is sufficiently large (deep), the focus of the linear beam 610 eis positioned not only at the interface between the first layer 57 a andthe second layer 57 b or in the vicinity thereof but also across theentire first layer 57 a in the thickness direction, the entire secondlayer 57 b in the thickness direction, or both the entire first layer 57a and the entire second layer 57 b in the thickness directions in somecases.

Note that as the excimer laser, a laser having a wavelength of 308 nm orlonger is preferably used. When the wavelength is 308 nm or longer, thelaser light that is necessary for processing can be sufficientlytransmitted even when a glass substrate is used for the support 56 b.

The substrate reversing unit 630 illustrated in FIG. 21 is a unit forturning the stack 56 upside down. For example, the substrate reversingunit 630 can include transfer rollers between which the stack 56 issandwiched from above and below and the transfer rollers can include arotatable mechanism. Note that the structure of the substrate reversingunit 630 is not limited thereto, and the transfer rollers between whichthe stack 56 is sandwiched from above and below may be placed in aspiral, or the substrate reversing unit 630 may include a transfer armwhich is capable of reversing.

In the stack 56 after passing through the substrate reversing unit 630,the member 56 a to be peeled is positioned on the upper side asillustrated in FIG. 21.

The tape reel 602 can unreel the support 601 in a rolled sheet form. Thespeed at which the support 601 is unreeled is preferably adjustable.When the speed is set relatively low, for example, failure in peeling ofthe stack or a crack in a peeled member can be inhibited.

The wind-up reel 683 can wind up the stack 59.

The tape reel 602 and the wind-up reel 683 can apply tension to thesupport 601.

The support 601 is unreeled continuously or intermittently. It ispreferable to unreel the support 601 continuously because peeling can beperformed at a uniform speed and with a uniform force. In a peelingprocess, the peeling preferably proceeds successively without a stop inthe middle, and further preferably, the peeling proceeds at a constantspeed. When the peeling stops in the middle of the process and then thepeeling resumes from the same region, distortion or the like occurs inthe region, unlike in the case where the peeling successively proceeds.Thus, a minute structure of the region or the characteristics of anelectronic device or the like in the region is/are changed, which mightinfluence display of a display device, for example.

As the support 601, a film in a rolled sheet form made of an organicresin, a metal, an alloy, glass, or the like can be used.

In FIG. 21, the support 601 is a member that constitutes a device to befabricated (e.g., a flexible device) together with the member 56 a to bepeeled, which is typified by a flexible substrate. The support 601 maybe a member that does not constitute the device to be fabricated, whichis typified by a carrier tape.

The delivery direction of the support 601 can be changed by thedirection changing roller 604. In the example illustrated in FIG. 21,the direction changing roller 604 is positioned between the tape reel602 and the press roller 606.

The support 601 is bonded to the stack 56 (the member 56 a to be peeled)by the press roller 606 and the transfer roller 646.

In the structure illustrated in FIG. 21, the support 601 can beprevented from being in contact with the stack 56 before reaching thepress roller 606. Accordingly, air bubbles can be inhibited from beingincluded between the support 601 and the stack 56.

The press roller 606 is rotated by a driving portion (e.g., a motor)which is not illustrated. When the press roller 606 rotates, the forceof peeling the member 56 a to be peeled is applied to the stack 56;thus, the member 56 a to be peeled is peeled. At this time, preferably,a peeling trigger has been formed in the stack 56. Peeling of the member56 a to be peeled starts from the peeling trigger. As a result, thestack 56 is divided into the member 56 a to be peeled and the support 56b.

The mechanism that peels the member 56 a to be peeled from the stack 56is not limited to the press roller 606, and a structure body having aconvex surface (or a convex curved surface or a convex-shaped curvedsurface) can be used. For example, a cylindrical (including circularcylindrical, right circular cylindrical, elliptic cylindrical, paraboliccylindrical, and the like) or spherical structure body can be used. Aroller such as a drum-shaped roller can be used, for example. Examplesof the shape of the structure body include a column with a bottomsurface constituted by a curved line (e.g., a cylinder with a perfectcircle-shaped bottom surface or an elliptic cylinder with anellipse-shaped bottom surface), and a column with a bottom surfaceconstituted by a curved line and a straight line (e.g., a column with asemicircular bottom surface or a semi-elliptical bottom surface). Whenthe shape of the structure body is any of such columns, the convexsurface corresponds to a curved surface of the column.

As a material for the structure body, a metal, an alloy, an organicresin, rubber, and the like can be given. The structure body may have aspace or a hollow inside. As the rubber, natural rubber, urethanerubber, nitrile rubber, neoprene rubber, and the like can be given. Inthe case of using rubber, it is preferable to use a material unlikely tobe charged by friction or peeling or to take countermeasures to preventstatic electricity. For example, the press roller 606 illustrated inFIG. 21 includes a hollow cylinder 606 a formed using rubber or anorganic resin and a circular cylinder 606 b formed using a metal or analloy and positioned inside the cylinder 606 a.

The rotation speed of the press roller 606 is preferably adjustable. Byadjusting the rotation speed of the press roller 606, the yield ofpeeling can be further increased.

The press roller 606 and the plurality of transfer rollers may bemovable in at least one direction (e.g., vertically, horizontally, orback and forth). The distance between the convex surface of the pressroller 606 and a supporting surface of the transfer roller is preferablyadjustable because peeling can be performed on stacks with a variety ofthicknesses.

There is no particular limitation on an angle at which the press roller606 bends back the support 601. FIG. 21 illustrates an example where thepress roller 606 bends back the support 601 at an obtuse angle.

The stack fabrication apparatus illustrated in FIG. 21 further includesa roller 617. The roller 617 can deliver the support 601 from the pressroller 606 to the wind-up reel 683 along the convex surface.

The roller 617 is movable in one or more directions.

The roller 617 can apply tension to the support 601 by moving the shaftof the roller 617. That is, the roller 617 is also referred to as atension roller. Specifically, the support 601 can be pulled in thedelivery direction changed with the press roller 606.

Moving the shaft of the roller 617 enables the roller 617 to control theangle at which the press roller 606 bends back the support 601.

The roller 617 can bend back the support 601 to change the deliverydirection of the support 601. For example, the delivery direction of thesupport 601 may be changed to the horizontal direction. Alternatively,after the roller 617 bends back the support 601 to change the deliverydirection of the support 601, the delivery direction of the support 601may be further changed to the horizontal direction by a directionchanging roller 607 located between the roller 617 and the wind-up reel683.

The stack fabrication apparatus illustrated in FIG. 21 further includesguide rollers (e.g., guide rollers 631, 632, and 633), a wind-up reel613, a liquid feeding mechanism 659, a drying mechanism 614, andionizers (ionizers 639 and 620).

The stack fabrication apparatus may include a guide roller that guidesthe support 601 to the wind-up reel 683. One guide roller may be used,or a plurality of guide rollers may be used. Like the guide roller 632,the guide roller may be capable of applying tension to the support 601.

A tape 600 (also called separate film) may be bonded to at least onesurface of the support 601. In this case, the stack fabricationapparatus preferably includes a reel that can wind up the tape 600bonded to one surface of the support 601. FIG. 21 illustrates an examplein which the wind-up reel 613 is positioned between the tape reel 602and the press roller 606. Furthermore, the stack fabrication apparatusmay include a guide roller 634. The guide roller 634 can guide the tape600 to the wind-up reel 613.

The stack fabrication apparatus may include the drying mechanism 614.Since a functional element (e.g., a transistor or a thin film integratedcircuit) included in the member 56 a to be peeled is vulnerable tostatic electricity, it is preferable that a liquid be fed to aninterface between the member 56 a to be peeled and the support 56 bbefore peeling or that the peeling be performed while a liquid is fed tothe interface. Furthermore, the presence of the liquid in the portionwhere the peeling proceeds can decrease the force required for thepeeling. The peeling can be performed while a liquid is fed to theinterface with the use of the liquid feeding mechanism 659. Since awatermark might be formed if the liquid is vaporized while being adheredto the member 56 a to be peeled, the liquid is preferably removedimmediately after the peeling. Thus, blowing is preferably performed onthe member 56 a to be peeled including a functional element to remove adroplet left on the member 56 a to be peeled. Therefore, watermarkgeneration can be suppressed. Furthermore, a carrier plate 609 may beprovided to prevent slack in the support 601.

It is preferable that an air flow downward along the inclination of thesupport 601 so that the droplet drips down while the support 601 istransferred in an oblique direction relative to the horizontal plane.

Although the transfer direction of the support 601 can also beperpendicular to the horizontal plane, the transfer direction that isoblique to the horizontal plane enables higher stability and lessshaking of the support 601 during the transfer.

During the process, a static eliminator included in the stackfabrication apparatus is preferably used at a position where staticelectricity might be generated. There is no particular limitation on thestatic eliminator, and for example, a corona discharge ionizer, a softX-ray ionizer, or an ultraviolet ionizer can be used.

For example, it is preferable that the stack fabrication apparatus beprovided with an ionizer and static elimination be performed by sprayingthe member 56 a to be peeled with air, a nitrogen gas, or the like fromthe ionizer to reduce the influence of static electricity on thefunctional element. It is particularly preferable to use the ionizer ina step of bonding two members to each other and a step of dividing onemember.

For example, the stack 56 is preferably divided into the member 56 a tobe peeled and the support 56 b while the vicinity of the interfacebetween the member 56 a to be peeled and the support 56 b is irradiatedwith ions using the ionizer 639 to remove static electricity.

The stack fabrication apparatus may include a substrate load cassette641 and a substrate unload cassette 642. For example, the stack 56 canbe supplied to the substrate load cassette 641. The substrate loadcassette 641 can supply the stack 56 to the transfer mechanism or thelike. Furthermore, the support 56 b can be supplied to the substrateunload cassette 642.

A tape reel 672 can unreel the support 671 in a rolled sheet form. Forthe support 671, a material similar to that for the support 601 can beused.

The tape reel 672 and the wind-up reel 683 can apply tension to thesupport 671.

The stack fabrication apparatus may include guide rollers 677, 678, and679 that guide the support 671 to the wind-up reel 683.

The delivery direction of the support 671 can be changed by thedirection changing roller 676.

A press roller 675 can bond the member 56 a to be peeled to the support671 that is unreeled by the tape reel 672 while applying pressure tothem. Accordingly, inclusion of air bubbles between the support 671 andthe member 56 a to be peeled can be inhibited.

A separation tape 670 may be bonded to at least one surface of thesupport 671. A reel 673 can wind up the separation tape 670. A guideroller 674 can guide the separation tape 670 to the reel 673.

The fabricated stack 59 may be wound up or cut. FIG. 21 illustrates anexample in which the wind-up reel 683 winds up the stack 59. A guideroller guiding the stack 59 to the wind-up reel 683, such as guiderollers 665 and 666, may be provided.

In the stack fabrication apparatus illustrated in FIG. 21, the member 56a to be peeled is peeled from the stack 56 by the press roller 606 andthe member 56 a to be peeled can be transferred to the support 671 bythe press roller 675.

This embodiment can be combined with the other embodiments and examplesas appropriate.

Embodiment 4

Described in this embodiment is a metal oxide applicable to a transistordisclosed in one embodiment of the present invention. In particular,details about a metal oxide and a cloud-aligned composite (CAC)-OS aredescribed below.

A CAC-OS or a CAC-metal oxide has a conducting function in a part of thematerial and has an insulating function in a part of the material; as awhole, the CAC-OS or the CAC-metal oxide has a function of asemiconductor. Note that in the case where the CAC-OS or the CAC-metaloxide is used in a channel formation region of a transistor, theconducting function is to allow electrons (or holes) serving as carriersto flow, and the insulating function is to not allow electrons servingas carriers to flow. By the complementary action of the conductingfunction and the insulating function, the CAC-OS or the CAC-metal oxidecan have a switching function (On/Off function). In the CAC-OS or theCAC-metal oxide, separation of the functions can maximize each function.

Furthermore, the CAC-OS or the CAC-metal oxide includes conductiveregions and insulating regions. The conductive regions have theabove-described conducting function, and the insulating regions have theabove-described insulating function. Furthermore, in some cases, theconductive regions and the insulating regions in the material areseparated at the nanoparticle level. Furthermore, in some cases, theconductive regions and the insulating regions are unevenly distributedin the material. Furthermore, the conductive regions are observed to becoupled in a cloud-like manner with their boundaries blurred, in somecases.

Furthermore, in the CAC-OS or the CAC-metal oxide, the conductiveregions and the insulating regions each have a size greater than orequal to 0.5 nm and less than or equal to 10 nm, preferably greater thanor equal to 0.5 nm and less than or equal to 3 nm, and are dispersed inthe material, in some cases.

Furthermore, the CAC-OS or the CAC-metal oxide includes componentshaving different bandgaps. For example, the CAC-OS or the CAC-metaloxide includes a component having a wide gap due to the insulatingregion and a component having a narrow gap due to the conductive region.When carriers flow in this composition, carriers mainly flow in thecomponent having a narrow gap. Furthermore, the component having anarrow gap complements the component having a wide gap, and carriersalso flow in the component having a wide gap in conjunction with thecomponent having a narrow gap. Therefore, in the case where theabove-described CAC-OS or CAC-metal oxide is used in a channel formationregion of a transistor, the transistor in the on state can achieve highcurrent driving capability, that is, a high on-state current and highfield-effect mobility.

In other words, the CAC-OS or the CAC-metal oxide can also be called amatrix composite or a metal matrix composite.

A CAC-OS refers to one composition of a material in which elementsconstituting a metal oxide are unevenly distributed with a size greaterthan or equal to 0.5 nm and less than or equal to 10 nm, preferablygreater than or equal to 1 nm and less than or equal to 2 nm, or asimilar size, for example. Note that a state in which one or more metalelements are unevenly distributed and regions including the metalelement(s) are mixed with a size greater than or equal to 0.5 nm andless than or equal to 10 nm, preferably greater than or equal to 1 nmand less than or equal to 2 nm, or a similar size in a metal oxide ishereinafter referred to as a mosaic pattern or a patch-like pattern.

Note that the metal oxide preferably contains at least indium. It isparticularly preferable that the metal oxide contain indium and zinc.Moreover, in addition to these, one kind or a plurality of kindsselected from aluminum, gallium, yttrium, copper, vanadium, beryllium,boron, silicon, titanium, iron, nickel, germanium, zirconium,molybdenum, lanthanum, cerium, neodymium, hafnium, tantalum, tungsten,magnesium, and the like may be contained.

For instance, a CAC-OS in an In—Ga—Zn oxide (an In—Ga—Zn oxide in theCAC-OS may be particularly referred to as CAC-IGZO) has a composition inwhich materials are separated into indium oxide (hereinafter InO_(X1)(X1 is a real number greater than 0)) or indium zinc oxide (hereinafterIn_(X2)Zn_(Y2)O_(Z2) (X2, Y2, and Z2 are real numbers greater than 0))and gallium oxide (hereinafter GaO_(X3) (X3 is a real number greaterthan 0)) or gallium zinc oxide (hereinafter Ga_(X4)Zn_(Y4)O_(Z4) (X4,Y4, and Z4 are real numbers greater than 0)), for example, so that amosaic pattern is formed, and mosaic-like InO_(X1) orIn_(X2)Zn_(Y2)O_(Z2) is evenly distributed in the film (which ishereinafter also referred to as cloud-like).

That is, the CAC-OS is a composite metal oxide having a composition inwhich a region including GaO_(X3) as a main component and a regionincluding In_(X2)Zn_(Y2)O_(Z2) or InO_(X1) as a main component aremixed. Note that in this specification, for example, when the atomicratio of In to an element M in a first region is larger than the atomicratio of In to the element M in a second region, the first region isregarded as having a higher In concentration than the second region.

Note that IGZO is a commonly known name and sometimes refers to onecompound formed of In, Ga, Zn, and O. A typical example is a crystallinecompound represented by InGaO₃(ZnO)_(m1) (m1 is a natural number) orIn_((1+x0))Ga_((1-x0))O₃(ZnO)_(m0) (−1≤x0≤1; m0 is a given number).

The above crystalline compound has a single crystal structure, apolycrystalline structure, or a c-axis aligned crystal (CAAC) structure.Note that the CAAC structure is a crystal structure in which a pluralityof IGZO nanocrystals have c-axis alignment and are connected on the a-bplane without alignment.

On the other hand, the CAC-OS relates to the material composition of ametal oxide. The CAC-OS refers to a composition in which, in thematerial composition containing In, Ga, Zn, and O, some regions thatinclude Ga as a main component and are observed as nanoparticles andsome regions that include In as a main component and are observed asnanoparticles are randomly dispersed in a mosaic pattern. Therefore, thecrystal structure is a secondary element for the CAC-OS.

Note that the CAC-OS is regarded as not including a stacked-layerstructure of two or more kinds of films with different compositions. Forexample, a two-layer structure of a film including In as a maincomponent and a film including Ga as a main component is not included.

Note that a clear boundary cannot sometimes be observed between theregion including GaO_(X3) as a main component and the region includingIn_(X2)Zn_(Y2)O_(Z2) or InO_(X1) as a main component.

Note that in the case where one kind or a plurality of kinds selectedfrom aluminum, yttrium, copper, vanadium, beryllium, boron, silicon,titanium, iron, nickel, germanium, zirconium, molybdenum, lanthanum,cerium, neodymium, hafnium, tantalum, tungsten, magnesium, and the likeare contained instead of gallium, the CAC-OS refers to a composition inwhich some regions that include the metal element(s) as a main componentand are observed as nanoparticles and some regions that include In as amain component and are observed as nanoparticles are randomly dispersedin a mosaic pattern.

The CAC-OS can be formed by a sputtering method under a condition wherea substrate is not heated intentionally, for example. Moreover, in thecase of forming the CAC-OS by a sputtering method, any one or moreselected from an inert gas (typically, argon), an oxygen gas, and anitrogen gas are used as a film formation gas. Furthermore, the ratio ofthe flow rate of an oxygen gas to the total flow rate of the filmformation gas at the time of film formation is preferably as low aspossible, and for example, the flow rate ratio of the oxygen gas ispreferably higher than or equal to 0% and lower than 30%, furtherpreferably higher than or equal to 0% and lower than or equal to 10%.

The CAC-OS is characterized in that no clear peak is observed inmeasurement using θ/2θ scan by an Out-of-plane method, which is one ofX-ray diffraction (XRD) measurement methods. That is, it is found fromthe X-ray diffraction that no alignment in the a-b plane direction andthe c-axis direction is observed in a measured region.

In addition, in an electron diffraction pattern of the CAC-OS which isobtained by irradiation with an electron beam with a probe diameter of 1nm (also referred to as a nanobeam electron beam), a ring-likehigh-luminance region and a plurality of bright spots in the ring regionare observed. It is therefore found from the electron diffractionpattern that the crystal structure of the CAC-OS includes an nc(nano-crystal) structure with no alignment in the plan-view directionand the cross-sectional direction.

Moreover, for example, it can be checked by EDX mapping obtained usingenergy dispersive X-ray spectroscopy (EDX) that the CAC-OS in theIn—Ga—Zn oxide has a composition in which regions including GaO_(X3) asa main component and regions including In_(X2)Zn_(Y2)O_(Z2) or InO_(X1)as a main component are unevenly distributed and mixed.

The CAC-OS has a composition different from that of an IGZO compound inwhich the metal elements are evenly distributed, and has characteristicsdifferent from those of the IGZO compound. That is, the CAC-OS has acomposition in which regions including GaO_(X3) or the like as a maincomponent and regions including In_(X2)Zn_(Y2)O_(Z2) or InO_(X1) as amain component are phase-separated from each other and form a mosaicpattern.

Here, a region including In_(X2)Zn_(Y2)O_(Z2) or InO_(X1) as a maincomponent is a region whose conductivity is higher than that of a regionincluding GaO_(X3) or the like as a main component. In other words, whencarriers flow through the regions including In_(X2)Zn_(Y2)O_(Z2) orInO_(X1) as a main component, the conductivity of an oxide semiconductoris exhibited. Accordingly, when the regions includingIn_(X2)Zn_(Y2)O_(Z2) or InO_(X1) as a main component are distributed inan oxide semiconductor like a cloud, high field-effect mobility (μ) canbe achieved.

In contrast, a region including GaO_(X3) or the like as a main componentis a region whose insulating property is higher than that of a regionincluding In_(X2)Zn_(Y2)O_(Z2) or InO_(X1) as a main component. In otherwords, when regions containing GaO_(X3) or the like as a main componentare distributed in an oxide semiconductor, leakage current can besuppressed and favorable switching operation can be achieved.

Accordingly, when the CAC-OS is used for a semiconductor element, theinsulating property derived from GaO_(X3) or the like and theconductivity derived from In_(X2)Zn_(Y2)O_(Z2) or InO_(X1) complementeach other, whereby a high on-state current (I_(on)) and highfield-effect mobility (μ) can be achieved.

Moreover, a semiconductor element using the CAC-OS has high reliability.Thus, the CAC-OS is most suitable for a variety of semiconductor devicessuch as displays.

This embodiment can be combined with the other embodiments and examplesas appropriate.

Embodiment 5

In this embodiment, electronic devices of one embodiment of the presentinvention will be described with reference to FIG. 23 and FIG. 24.

A thin, lightweight, and highly reliable electronic device can befabricated according to one embodiment of the present invention. Ahighly reliable electronic device with a curved surface can befabricated according to one embodiment of the present invention. Inaddition, a flexible and highly reliable electronic device can befabricated according to one embodiment of the present invention.

Examples of electronic devices include a digital camera, a digital videocamera, a digital photo frame, a mobile phone, a portable game console,a portable information terminal, and an audio reproducing device inaddition to electronic devices provided with a comparatively largescreen, such as a television device, a desktop or laptop personalcomputer, a monitor for a computer and the like, digital signage, and alarge game machine such as a pachinko machine.

The electronic device of this embodiment can be incorporated along acurved surface of an inside wall or an outside wall of a house or abuilding or the interior or the exterior of a car.

The electronic device of this embodiment may include an antenna. When asignal is received by the antenna, an image, information, or the likecan be displayed on the display portion. Moreover, when the electronicdevice includes an antenna and a secondary battery, the antenna may beused for contactless power transmission.

The electronic device of this embodiment may include a sensor (a sensorhaving a function of measuring force, displacement, position, speed,acceleration, angular velocity, rotational frequency, distance, light,liquid, magnetism, temperature, chemical substance, sound, time,hardness, electric field, current, voltage, electric power, radioactiverays, flow rate, humidity, gradient, oscillation, smell, or infraredrays).

The electronic device of this embodiment can have a variety offunctions. For example, the electronic device can have a function ofdisplaying a variety of information (e.g., a still image, a movingimage, and a text image) on the display portion, a touch panel function,a function of displaying a calendar, date, time, and the like, afunction of executing a variety of software (programs), a wirelesscommunication function, and a function of reading out a program or datastored in a recording medium.

FIG. 23(A) illustrates an example of a television device. In atelevision device 7100, a display portion 7000 is incorporated into ahousing 7101. Here, a structure where the housing 7101 is supported by astand 7103 is shown.

The display device of one embodiment of the present invention can beused for the display portion 7000.

The television device 7100 illustrated in FIG. 23(A) can be operatedwith an operation switch provided in the housing 7101 or a separateremote controller 7111. Alternatively, the display portion 7000 mayinclude a touch sensor, in which case the television device 7100 can beoperated by touch on the display portion 7000 with a finger or the like.The remote controller 7111 may include a display portion that displaysinformation to be output from the remote controller 7111. With operationkeys or a touch panel included in the remote controller 7111, channelsand volume can be controlled and images displayed on the display portion7000 can be controlled.

Note that the television device 7100 is configured to include areceiver, a modem, and the like. A general television broadcast can bereceived with the receiver. When the television device is connected to acommunication network with or without wires via the modem, one-way (froma transmitter to a receiver) or two-way (e.g., between a transmitter anda receiver or between receivers) information communication can also beperformed.

FIG. 23(B) illustrates an example of a laptop personal computer. Alaptop personal computer 7200 includes a housing 7211, a keyboard 7212,a pointing device 7213, an external connection port 7214, and the like.The display portion 7000 is incorporated into the housing 7211.

The display device of one embodiment of the present invention can beused for the display portion 7000.

FIGS. 23(C) and 23(D) illustrate examples of digital signage.

Digital signage 7300 illustrated in FIG. 23(C) includes a housing 7301,the display portion 7000, a speaker 7303, and the like. The digitalsignage 7300 can also include an LED lamp, operation keys (including apower switch or an operation switch), a connection terminal, a varietyof sensors, a microphone, and the like.

FIG. 23(D) illustrates digital signage 7400 mounted on a cylindricalpillar 7401. The digital signage 7400 includes the display portion 7000provided along a curved surface of the pillar 7401.

In FIGS. 23(C) and 23(D), the display device of one embodiment of thepresent invention can be used for the display portion 7000.

The larger display portion 7000 can increase the amount of informationthat can be provided at a time. In addition, the larger display portion7000 attracts more attention, and for example, the effectiveness of theadvertisement can be increased.

It is preferable to use a touch panel in the display portion 7000, inwhich case intuitive operation by a user in addition to display of animage or a moving image on the display portion 7000 is possible.Moreover, for an application for providing information such as routeinformation or traffic information, usability can be enhanced byintuitive operation.

Furthermore, as illustrated in FIGS. 23(C) and 23(D), it is preferredthat the digital signage 7300 or the digital signage 7400 be capable ofworking with an information terminal 7311 or an information terminal7411 such as a user's smartphone through wireless communication. Forexample, information of an advertisement displayed on the displayportion 7000 can be displayed on a screen of the information terminal7311 or the information terminal 7411. Moreover, display on the displayportion 7000 can be switched by operating the information terminal 7311or the information terminal 7411.

It is also possible to make the digital signage 7300 or the digitalsignage 7400 execute a game with the use of the screen of theinformation terminal 7311 or the information terminal 7411 as anoperation means (a controller). Thus, an unspecified number of peoplecan join in and enjoy the game concurrently.

FIGS. 24(A) to 24(E) illustrate electronic devices. These electronicdevices include a housing 9000, a display portion 9001, a speaker 9003,an operation key 9005 (including a power switch or an operation switch),a connection terminal 9006, a sensor 9007 (a sensor having a function ofmeasuring force, displacement, position, speed, acceleration, angularvelocity, rotational frequency, distance, light, liquid, magnetism,temperature, chemical substance, sound, time, hardness, electric field,current, voltage, power, radiation, flow rate, humidity, gradient,oscillation, odor, or infrared rays), a microphone 9008, and the like.

The display device fabricated using one embodiment of the presentinvention can be favorably used for the display portion 9001. Thus, theelectronic devices can be fabricated with a high yield.

The electronic devices illustrated in FIGS. 24(A) to 24(E) can have avariety of functions. For example, they can have a function ofdisplaying a variety of information (e.g., a still image, a movingimage, and a text image) on the display portion, a touch panel function,a function of displaying a calendar, date, time, or the like, a functionof controlling processing with a variety of software (programs), awireless communication function, a function of being connected to avariety of computer networks with a wireless communication function, afunction of transmitting and receiving a variety of data with a wirelesscommunication function, and a function of reading a program or datastored in a memory medium and displaying it on the display portion. Notethat the functions which the electronic devices illustrated in FIGS.24(A) to 24(E) have are not limited to these, and they may have otherfunctions.

FIG. 24(A) and FIG. 24(B) are perspective views illustrating awristwatch-type portable information terminal 9200 and a wristwatch-typeportable information terminal 9201, respectively.

The portable information terminal 9200 illustrated in FIG. 24(A) iscapable of executing a variety of applications such as mobile phonecalls, e-mailing, text viewing and writing, music reproduction, Internetcommunication, and computer games. In addition, the display portion 9001is provided such that its display surface is curved, and display can beperformed along the curved display surface. Moreover, the portableinformation terminal 9200 can perform standards-based near fieldcommunication. For example, mutual communication with a headset capableof wireless communication enables hands-free calling. Furthermore, theportable information terminal 9200 includes the connection terminal 9006and can exchange data directly with another information terminal througha connector. Power charging through the connection terminal 9006 is alsopossible. Note that the charging operation may be performed by wirelesspower feeding without through the connection terminal 9006.

Unlike in the portable information terminal illustrated in FIG. 24(A),the display surface of the display portion 9001 is not curved in theportable information terminal 9201 illustrated in FIG. 24(B).Furthermore, the external shape of the display portion of the portableinformation terminal 9201 is a non-rectangular shape (a circular shapein FIG. 24(B)).

FIGS. 24(C) to 24(E) are perspective views illustrating a foldableportable information terminal 9202. Note that FIG. 24(C) is aperspective view of the portable information terminal 9202 in an openstate; FIG. 24(D) is a perspective view of the portable informationterminal 9202 that is being changed from one of an open state and afolded state to the other; and FIG. 24(E) is a perspective view of theportable information terminal 9202 in a folded state.

The portable information terminal 9202 is highly portable in a foldedstate and has high display browsability due to a seamless large displayregion in an open state. The display portion 9001 included in theportable information terminal 9202 is supported by three housings 9000joined with hinges 9055. By being bent between two housings 9000 withthe hinges 9055, the portable information terminal 9202 can bereversibly changed in shape from an open state to a folded state. Forexample, the portable information terminal 9202 can be bent with aradius of curvature greater than or equal to 1 mm and less than or equalto 150 mm.

This embodiment can be combined with the other embodiments and examplesas appropriate.

Example 1

In this example, results of peeling a functional layer from a formationsubstrate by the peeling method of one embodiment of the presentinvention will be described.

<Sample Fabrication>

First, steps before formation of a functional layer over a formationsubstrate will be described with reference to FIG. 4, and then, the stepof forming the functional layer over the formation substrate and thesubsequent steps will be described with reference to FIG. 2.

In this example, two kinds of samples (Sample A1 and Sample A2) whichwere different in the thickness of a metal layer formed over theformation substrate were fabricated. Three of each of Samples A1 andSamples A2 were fabricated; one was used for cross-sectional observationbefore peeling, another was used for XPS analysis after peeling, and theother was used for cross-sectional observation after peeling.

First, as illustrated in FIG. 4(A), the metal layer 102 was formed overthe formation substrate 101.

As the formation substrate 101, an approximately 0.7-mm-thick glasssubstrate was used. As the metal layer 102, a titanium film was formedby a sputtering method. At the time of the formation of the titaniumfilm, an argon gas with a flow rate of 100 sccm was used as the processgas, the pressure was 0.3 Pa, and the power was 58 kW. The thickness ofthe titanium film of Sample A1 was approximately 35 nm, and thethickness of the titanium film of Sample A2 was approximately 20 nm.

Next, H₂O plasma treatment was performed on a surface of the metal layer102 (FIG. 4(B)) to form the layer 103 containing a metal oxide (FIG.4(C)). In the H₂O plasma treatment, the bias power was 4500 W, the ICPpower was 0 W, the pressure was 15 Pa, the treatment time was 600 sec,and water vapor with a flow rate of 250 sccm was used as the processgas. In this example, the H₂O plasma treatment oxidized the surface sideof the metal layer 102. Thus, a stacked-layer structure of the titaniumfilm over the formation substrate 101 and the titanium oxide film overthe titanium film was formed as the layer 103 containing a metal oxide.

Next, as illustrated in FIG. 4(D), the first layer 122 was formed overthe layer 103 containing a metal oxide.

The first layer 122 was formed using a photosensitive materialcontaining a polyimide resin precursor. The material was applied to athickness of approximately 3

Next, the layer 103 containing a metal oxide and the first layer 122were subjected to baking in a nitrogen-containing atmosphere (while anitrogen gas was supplied) at 450° C. for one hour, whereby the metalcompound layer 105 and the resin layer 123 were formed (FIG. 4(E1)).

Next, as illustrated in FIG. 2(A), the functional layer 135 was formedover the resin layer 123, and a UV-peeling tape (corresponding to theadhesive layer 145 and the substrate 146 in FIG. 2(A)) was bonded ontothe functional layer 135.

As the functional layer 135, a stacked-layer structure including asilicon oxynitride film and a silicon nitride film was formed. Thethickness of the stacked-layer structure was approximately 650 nm.

<Cross-Sectional Observation of Sample Before Peeling>

Next, the results of cross-sectional STEM observation of Sample A1 andSample A2 before peeling will be described. Note that the results ofeach sample are those of cross-sectional observation after the formationof the metal compound layer 105 and the resin layer 123. Specifically,cross-sectional STEM observation of Sample A1 was performed after theformation of the functional layer 135, and cross-sectional STEMobservation of Sample A2 was performed after the formation of the resinlayer 123.

FIG. 25(A) shows results of the cross-sectional observation of SampleA1. The metal compound layer 105 appeared to be divided into threelayers, and it was suggested that the metal compound layer 105 had athree-layer structure as shown in FIG. 4(E2). The metal compound layer105 had a thickness of approximately 45 nm, the first compound layer 111had a thickness of approximately 13 nm, the second compound layer 112had a thickness of approximately 8 nm, and the third compound layer 113had a thickness of approximately 24 nm. Note that the thicknesses of thelayers were obtained by using a length measuring function of the STEM ineach example.

FIG. 25(B) shows results of the cross-sectional observation of SampleA2. The metal compound layer 105 appeared to be divided into two layers,and it was suggested that the metal compound layer 105 had a two-layerstructure as shown in FIG. 4(E3). The metal compound layer 105 had athickness of approximately 30 nm, the first compound layer 111 had athickness of approximately 21 nm, and the second compound layer 112 hada thickness of approximately 9 nm.

<Peeling>

Next, as illustrated in FIG. 2(B), irradiation with the laser light 155was performed from the formation substrate 101 side. Then, the resinlayer 123 was peeled from the formation substrate 101.

As a laser oscillator for the laser light, a XeCl excimer laser with awavelength of 308 nm was used. The short-axis light-condensing width ofthe beam was 625 μm, the number of shots was 10, the repetition rate was60 Hz, the scanning speed was 3.75 mm/second, and the energy density wasapproximately 360 mJ/cm².

Note that the absorptance of light with a wavelength of 308 nm by theglass substrate used as the formation substrate 101 was approximately51%. The absorptance of light with a wavelength of 308 nm by thestacked-layer structure of the formation substrate 101 and the metalcompound layer 105 was approximately 87% in the case of Sample A1 (thethickness of the metal compound layer 105 was approximately 45 nm), andwas approximately 85% in the case of Sample A2 (the thickness of themetal compound layer 105 was approximately 30 nm). Thus, all of theinterface between the metal compound layer 105 and the resin layer 123,the inside of the metal compound layer 105, and the inside of the resinlayer 123 were presumably irradiated with the laser light.

In each of Sample A1 and Sample A2, the functional layer 135 wasfavorably peeled. In particular, the force required for peeling wassmaller in Sample A1 than in Sample A2.

<Cross-Sectional Observation of Sample after Peeling>

Next, cross-sectional STEM observation of Sample A1 and Sample A2 afterpeeling was performed. FIG. 26(A) shows cross-sectional observationresults of the formation substrate 101 side of Sample A1; FIG. 26(B)shows cross-sectional observation results of the substrate 146 side ofSample A1; and FIG. 26(C) shows cross-sectional observation results ofthe formation substrate 101 side of Sample A2.

From the results in FIGS. 25(A) and 25(B) and FIGS. 26(A) and 26(C), nosignificant difference was observed in the structure and thickness ofthe metal compound layer 105 before and after the peeling. In FIG.26(A), the metal compound layer 105 had a thickness of approximately 42nm, the first compound layer 111 had a thickness of approximately 12 nm,the second compound layer 112 had a thickness of approximately 6 nm, andthe third compound layer 113 had a thickness of approximately 24 nm. InFIG. 26(C), the metal compound layer 105 had a thickness ofapproximately 32 nm, the first compound layer 111 had a thickness ofapproximately 23 nm, and the second compound layer 112 had a thicknessof approximately 9 nm.

As shown in FIGS. 26(A) and 26(C), the resin layer 123 was not observedbetween the metal compound layer 105 and a coat layer (Coat) that wasformed for observation in either Sample A1 or Sample A2. As shown inFIG. 26(B), in Sample A1, the metal compound layer 105 was not observedbetween the resin layer 123 and the coat layer that was formed forobservation. Thus, separation probably occurred between the metalcompound layer 105 and the resin layer 123 as illustrated in FIG. 2(C1).Note that the black portion seen between the resin layer 123 and thecoat layer in FIG. 26(B) is film separation due to damage at the time ofthe cross-sectional observation.

<Depth-Direction Analysis of Sample after Peeling>

Next, XPS analysis was conducted on Sample A1 and Sample A2 afterpeeling to obtain the proportions of oxygen atoms (O), titanium atoms(Ti), nitrogen atoms (N), and silicon atoms (Si) in the metal compoundlayer 105 in the depth direction. Here, sputtering and measurement wereperformed from the surface side of the metal compound layer 105 that wasexposed by peeling.

FIG. 27(A) shows the XPS analysis results of Sample A1, and FIG. 27(B)shows the XPS analysis results of Sample A2. In FIGS. 27(A) and 27(B),the horizontal axis represents the sputtering time (Sputter Time) (min),and the vertical axis represents the quantitative value (atomic %).

From the XPS analysis results, it was checked that the metal compoundlayer 105 of Sample A1 had a three-layer structure as illustrated inFIG. 4(E2) and the metal compound layer 105 of Sample A2 had a two-layerstructure as illustrated in FIG. 4(E3).

Note that in the XPS analysis described in this specification and thelike, the boundary between the first layer and the second layer and theboundary between the second layer and the third layer in the metalcompound layer 105 were determined with the half value of the peak areaof an N1s spectrum. The boundary between the formation substrate 101 andthe metal compound layer 105 was determined with the half value of thepeak area of a Ti2p spectrum. However, for convenience of drawing adiagram, the shown boundaries might be deviated from the determinedpositions.

From FIGS. 27(A) and 27(B), it was found that a layer which had thehighest oxygen content among the layers included in the metal compoundlayer 105 was the first compound layer 111. The first compound layer 111contained oxygen more than titanium. As shown in FIG. 27(A), theproportion of oxygen contained in the first compound layer 111 of SampleA1 was approximately greater than or equal to 40 atomic % and less thanor equal to 70 atomic %. As shown in FIG. 27(B), the proportion ofoxygen contained in the first compound layer 111 of Sample A2 wasapproximately greater than or equal to 50 atomic % and less than orequal to 70 atomic %. The proportion of titanium contained in the firstcompound layer 111 of each sample was approximately greater than orequal to 30 atomic % and less than or equal to 45 atomic %.

From FIGS. 27(A) and 27(B), it was found that a layer which had thehighest nitrogen content among the layers included in the metal compoundlayer 105 was the second compound layer 112. As shown in FIG. 27(A), theproportion of nitrogen contained in the second compound layer 112 ofSample A1 was approximately greater than or equal to 10 atomic % andless than or equal to 20 atomic %. As shown in FIG. 27(B), theproportion of nitrogen contained in the second compound layer 112 ofSample A2 was approximately greater than or equal to 5 atomic % and lessthan or equal to 10 atomic %.

As shown in FIG. 27(A), the metal compound layer 105 included the thirdcompound layer 113 in Sample A1. The proportion of oxygen contained inthe third compound layer 113 of Sample A1 was approximately greater thanor equal to 30 atomic % and less than or equal to 40 atomic %.

In addition, the metal compound layer 105 contained almost no silicon;specifically, the proportion of silicon contained in the first compoundlayer 111 was approximately less than or equal to 5 atomic %.

The results of the XPS analysis revealed that the first compound layer111 contained titanium oxide (TiO_(a) (a>1)), the second compound layer112 contained titanium oxynitride (TiO_(b)N_(c) (b>0, c>0)), and thethird compound layer 113 contained titanium oxide (TiO_(e) (0<e<a)).

It was checked from the results in this example that the formationsubstrate 101 can be peeled at the interface between the metal compoundlayer 105 and the resin layer 123 by the peeling method of oneembodiment of the present invention.

In this example, the force required for peeling was smaller in SampleA1, in which the metal layer 102 was formed to be thick, than in SampleA2. The cross-sectional observation and the XPS analysis before andafter peeling showed a difference in the structure of the metal compoundlayer 105 between the two samples. Specifically, it was suggested thatthe peelability was affected by a difference between the two-layerstructure and the three-layer structure, a difference in the amount ofnitrogen contained in the second compound layer 112, and the like.

Example 2

In this example, results of peeling a functional layer from a formationsubstrate by the peeling method of one embodiment of the presentinvention will be described.

<Sample Fabrication>

First, steps before formation of a functional layer over a formationsubstrate will be described with reference to FIG. 1 and FIG. 5, andthen, the step of forming the functional layer over the formationsubstrate and the subsequent steps will be described with reference toFIG. 2.

In this example, two kinds of samples (Sample B1 and Sample B2) whichwere different in a formation method of the metal compound layer 105were fabricated. Two of each of Samples B1 and Samples B2 werefabricated; one was used for cross-sectional observation and the otherwas used for XPS analysis.

First, as illustrated in FIG. 1(A) and FIG. 5(A), the metal layer 102was formed over the formation substrate 101. In Sample B1, the metalnitride layer 104 was formed over the metal layer 102 (FIG. 5(A)).

As the formation substrate 101, an approximately 0.7-mm-thick glasssubstrate was used. As the metal layer 102, an approximately 20-nm-thicktitanium film was formed by a sputtering method. At the time of theformation of the titanium film, an argon gas with a flow rate of 100sccm was used as the process gas, the pressure was 0.3 Pa, and the powerwas 58 kW. As the metal nitride layer 104, an approximately 10-nm-thicktitanium nitride film was formed by a sputtering method. At the time ofthe formation of the titanium nitride film, a nitrogen gas with a flowrate of 210 sccm was used as the process gas, the pressure was 0.4 Pa,and the power was 10 kW.

Next, H₂O plasma treatment was performed on a surface of the metal layer102 or a surface of the metal nitride layer 104 (not shown). In the H₂Oplasma treatment, the bias power was 4500 W, the ICP power was 0 W, thepressure was 15 Pa, the treatment time was 120 sec (Sample B1) or 600sec (Sample B2), and water vapor with a flow rate of 250 sccm was usedas the process gas. In this example, the H₂O plasma treatment oxidizedthe surface side of the metal layer 102 or the surface side of the metalnitride layer 104 to form a layer containing a metal oxide. Thus, inSample B1, as the layer containing a metal oxide, a stacked-layerstructure of a titanium film over the formation substrate 101, atitanium nitride film over the titanium film, and a titanium oxide filmover the titanium nitride film was formed. In Sample B2, as the layercontaining a metal oxide, a stacked-layer structure of a titanium filmover the formation substrate 101 and a titanium oxide film over thetitanium film was formed.

Next, the first layer 122 was formed over the layer containing a metaloxide (FIG. 1(B) and FIG. 5(B)).

The first layer 122 was formed using a photosensitive materialcontaining a polyimide resin precursor. The material was applied to athickness of approximately 3 μm.

Next, the layer containing a metal oxide and the first layer 122 weresubjected to baking in a nitrogen-containing atmosphere (while anitrogen gas was supplied) at 450° C. for two hours, whereby the metalcompound layer 105 and the resin layer 123 were formed (FIG. 1(C1) andFIG. 5(C1)).

Next, as illustrated in FIG. 2(A), the functional layer 135 was formedover the resin layer 123, and a UV-peeling tape (corresponding to theadhesive layer 145 and the substrate 146 in FIG. 2(A)) was bonded ontothe functional layer 135.

As the functional layer 135, a stacked-layer structure including asilicon oxynitride film and a silicon nitride film was formed. Thethickness of the stacked-layer structure was approximately 650 nm.

<Cross-Sectional Observation of Sample>

Next, the results of cross-sectional STEM observation of Sample B1 andSample B2 will be described. Note that the results of each sample arethose of cross-sectional observation after the formation of the metalcompound layer 105 and the resin layer 123.

FIG. 28(A) shows results of the cross-sectional observation of Sample B1. The metal compound layer 105 appeared to be divided into threelayers, and it was suggested that the metal compound layer 105 had athree-layer structure as shown in FIG. 5(C2). The metal compound layer105 had a thickness of approximately 35 nm, the first compound layer 111had a thickness of approximately 9 nm, the second compound layer 112 hada thickness of approximately 11 nm, and the third compound layer 113 hada thickness of approximately 15 nm.

FIG. 28(B) shows results of the cross-sectional observation of SampleB2. The metal compound layer 105 appeared to be divided into threelayers, and it was suggested that the metal compound layer 105 had athree-layer structure as shown in FIG. 1(C2). The metal compound layer105 had a thickness of approximately 45 nm, the first compound layer 111had a thickness of approximately 15 nm, the second compound layer 112had a thickness of approximately 9 nm, and the third compound layer 113had a thickness of approximately 21 nm.

<Peeling>

Next, as illustrated in FIG. 2(B), irradiation with the laser light 155was performed from the formation substrate 101 side. Then, the resinlayer 123 was peeled from the formation substrate 101.

As a laser oscillator emitting the laser light 155, a XeCl excimer laserwith a wavelength of 308 nm was used. The short-axis light-condensingwidth of the beam was 625 μm, the number of shots was 10, the repetitionrate was 60 Hz, the scanning speed was 3.75 mm/second, and the energydensity was approximately 350 mJ/cm².

Note that water was fed to the peeling interface in the peeling.

In each of Sample B1 and Sample B2, the functional layer 135 wasfavorably peeled.

<Depth—Direction Analysis of Sample>

Next, XPS analysis was conducted on Sample B1 and Sample B2 to obtainthe proportions of oxygen atoms (O), titanium atoms (Ti), nitrogen atoms(N), and silicon atoms (Si) in the metal compound layer 105 in the depthdirection. Here, sputtering and measurement were performed from thesurface side of the metal compound layer 105.

FIG. 29(A) shows the XPS analysis results of Sample B 1, and FIG. 29(B)shows the XPS analysis results of Sample B2. In FIGS. 29(A) and 29(B),the horizontal axis represents the sputtering time (min), and thevertical axis represents the quantitative value (atomic %).

From the XPS analysis results, it was checked that the metal compoundlayer 105 of each of Sample B1 and Sample B2 had a three-layer structureas illustrated in FIG. 1(C2) and FIG. 5(C2).

From FIGS. 29(A) and 29(B), it was found that a layer which had thehighest oxygen content among the layers included in the metal compoundlayer 105 was the first compound layer 111. The first compound layer 111contained oxygen more than titanium. As shown in FIGS. 29(A) and 29(B),the proportion of oxygen contained in the first compound layer 111 ofeach of Sample B1 and Sample B2 was approximately greater than or equalto 40 atomic % and less than or equal to 70 atomic %. The proportion oftitanium contained in the first compound layer 111 of each of Sample B1and Sample B2 was approximately greater than or equal to 30 atomic % andless than or equal to 45 atomic %.

From FIGS. 29(A) and 29(B), it was found that a layer which had thehighest nitrogen content among the layers included in the metal compoundlayer 105 was the second compound layer 112. As shown in FIG. 29(A), theproportion of nitrogen contained in the second compound layer 112 ofSample B1 was approximately greater than or equal to 20 atomic % andless than or equal to 40 atomic %. As shown in FIG. 29(B), theproportion of nitrogen contained in the second compound layer 112 ofSample B2 was approximately greater than or equal to 10 atomic % andless than or equal to 20 atomic %.

As shown in FIG. 29(A), the proportion of oxygen contained in the thirdcompound layer 113 of Sample B1 was approximately greater than or equalto 30 atomic % and less than or equal to 70 atomic %. As shown in FIG.29(B), the proportion of oxygen contained in the third compound layer113 of Sample B2 was approximately greater than or equal to 30 atomic %and less than or equal to 40 atomic %.

In addition, the metal compound layer 105 contained almost no silicon;specifically, the proportion of silicon contained in the first compoundlayer 111 was approximately less than or equal to 5 atomic %.

The results of the XPS analysis revealed that the first compound layer111 contained titanium oxide (TiO_(a) (a>1)), the second compound layer112 contained titanium oxynitride (TiO_(b)N_(e) (b>0, c>0)), and thethird compound layer 113 contained titanium oxide (TiO_(e) (0<e<a)).

It was checked from the results in this example that the formationsubstrate 101 can be peeled at the interface between the metal compoundlayer 105 and the resin layer 123 by the peeling method of oneembodiment of the present invention.

In this example, the functional layer 135 was favorably peeled in eachof the two samples that were different in the fabrication method of themetal compound layer 105. The cross-sectional observation and the XPSanalysis showed that the two samples had commonalities in the structureof the metal compound layer 105. Specifically, it was suggested that thepeelability was affected by the use of the three-layer structure, thesufficient amount of nitrogen contained in the second compound layer112, and the like.

Example 3

In Example 1 and Example 2, it was checked by the XPS analysis thatnitrogen was contained in the metal compound layer 105. In this example,in which step the nitrogen enters the metal film or the metal compoundfilm was examined.

Two possible supply sources of nitrogen are the resin layer 123 and thenitrogen-containing atmosphere in baking. In this example, whether ornot nitrogen enters the metal film or the metal compound film byperforming baking in a nitrogen-containing atmosphere on the metal filmand the metal compound film without forming the resin layer 123 wasexamined.

<Sample Fabrication>

A method for fabricating samples of this example is described withreference to FIGS. 6(A), 6(B1), and 6(B2). In this example, two kinds ofsamples (Sample C1 and Sample C2) were fabricated. Two of Samples C1were formed; one was used for cross-sectional observation and the otherwas used for XPS analysis. One Sample C2 was formed to be used for XPSanalysis.

Sample C1 and Sample C2 were formed in such a manner that the metallayer 102 was formed over the formation substrate 101, baking wasperformed in a nitrogen-containing atmosphere without forming the firstlayer 122, and then, the metal compound layer 105 was formed.

In Sample C1, the metal layer 102 was formed over the formationsubstrate 101, the metal layer 102 was subjected to H₂O plasmatreatment, and then, baking in a nitrogen-containing atmosphere wasperformed to form the metal compound layer 105. In other words, inSample C1, the metal compound layer 105 was formed by performing bakingon the layer containing a metal oxide in a nitrogen-containingatmosphere. On the other hand, in Sample C2, H₂O plasma treatment wasnot performed on the metal layer 102. In Sample C2, the metal compoundlayer 105 was formed by performing baking on the metal layer 102 in anitrogen-containing atmosphere. Detailed fabrication conditions will bedescribed below.

First, as illustrated in FIG. 6(A), the metal layer 102 was formed overthe formation substrate 101.

As the formation substrate 101, an approximately 0.7-mm-thick glasssubstrate was used. As the metal layer 102, an approximately 35-nm-thicktitanium film was formed by a sputtering method. At the time of theformation of the titanium film, an argon gas with a flow rate of 100sccm was used as the process gas, the pressure was 0.3 Pa, and the powerwas 58 kW.

Next, in Sample C1, H₂O plasma treatment was performed on a surface ofthe metal layer 102 to form the layer containing a metal oxide. InSample C2, the plasma treatment was not performed. In the H₂O plasmatreatment, the bias power was 4500 W, the ICP power was 0 W, thepressure was 15 Pa, the treatment time was 600 sec, and water vapor witha flow rate of 250 sccm was used as the process gas. In this example,the H₂O plasma treatment oxidized the surface side of the metal layer102. Thus, a stacked-layer structure of the titanium film over theformation substrate 101 and the titanium oxide film over the titaniumfilm was formed as the layer containing a metal oxide.

Next, in Sample C1, the layer containing a metal oxide was subjected tobaking in a nitrogen-containing atmosphere (while a nitrogen gas wassupplied) at 450° C. for one hour, whereby the metal compound layer 105was formed. In Sample C2, the metal layer 102 was subjected to baking ina nitrogen-containing atmosphere (while a nitrogen gas was supplied) at450° C. for one hour, whereby the metal compound layer 105 was formed(FIG. 6(B1)).

In this manner, Sample C1 and Sample C2 were formed.

<Cross-Sectional Observation of Sample>

Next, the results of cross-sectional STEM observation of Sample C1 willbe described.

FIG. 30 shows results of the cross-sectional observation of Sample C1.The metal compound layer 105 appeared to be divided into three layers,and it was suggested that the metal compound layer 105 had a three-layerstructure as shown in FIG. 6(B2). The metal compound layer 105 had athickness of approximately 45 nm, the first compound layer 111 had athickness of approximately 13 nm, the second compound layer 112 had athickness of approximately 7 nm, and the third compound layer 113 had athickness of approximately 25 nm.

<Depth-Direction Analysis of Sample>

Next, XPS analysis was conducted on Sample C1 and Sample C2 to obtainthe proportions of oxygen atoms (O), titanium atoms (Ti), nitrogen atoms(N), and silicon atoms (Si) in the metal compound layer 105 in the depthdirection. Here, sputtering and measurement were performed from thesurface side of the metal compound layer 105.

FIG. 31(A) shows the XPS analysis results of Sample C1, and FIG. 31(B)shows the XPS analysis results of Sample C2. In FIGS. 31(A) and 31(B),the horizontal axis represents the sputtering time (min), and thevertical axis represents the quantitative value (atomic %).

From the XPS analysis results, it was checked that the metal compoundlayer 105 of each of Sample C1 and Sample C2 had a three-layer structureas illustrated in FIG. 6(B2).

From FIGS. 31(A) and 31(B), it was found that a layer which had thehighest oxygen content among the layers included in the metal compoundlayer 105 was the first compound layer 111. The first compound layer 111contained oxygen more than titanium. As shown in FIGS. 31(A) and 31(B),the proportion of oxygen contained in the first compound layer 111 ofeach sample was approximately greater than or equal to 40 atomic % andless than or equal to 70 atomic %. The proportion of titanium containedin the first compound layer 111 of each sample was approximately greaterthan or equal to 30 atomic % and less than or equal to 45 atomic %.

From FIGS. 31(A) and 31(B), it was found that a layer which had thehighest nitrogen content among the layers included in the metal compoundlayer 105 was the second compound layer 112. As shown in FIGS. 31(A) and31(B), the proportion of nitrogen contained in the second compound layer112 of each sample was approximately greater than or equal to 10 atomic% and less than or equal to 20 atomic %.

As shown in FIGS. 31(A) and 31(B), the proportion of oxygen contained inthe third compound layer 113 of each sample was approximately greaterthan or equal to 30 atomic % and less than or equal to 40 atomic %.

In addition, the metal compound layer 105 contained almost no silicon;specifically, the proportion of silicon contained in the first compoundlayer 111 was approximately less than or equal to 5 atomic %.

In this example, the metal compound layer 105 containing nitrogen wasformed by performing baking in a nitrogen-containing atmosphere evenwithout formation of a film to be a resin layer over the metal layer 102or the layer containing a metal oxide. It is thus presumable thatnitrogen entered the metal layer 102 or the layer containing a metaloxide from the atmosphere during the baking. Furthermore, since themetal compound layer 105 contained oxygen regardless of whether the H₂Oplasma treatment was performed, it is presumable that oxygen wascontained in the atmosphere during the baking.

A sample was fabricated in such a manner that the baking in anitrogen-containing atmosphere at 450° C. for one hour in Sample A1 inExample 1 was changed into baking in a mixed atmosphere of nitrogen andoxygen (oxygen concentration: 20%) at 450° C. for one hour, in whichcase the peelability was poorer than that in Sample A1 in Example 1.From the results of the cross-sectional STEM observation and the XPSanalysis, it was checked that the metal compound layer 105 of thissample was a single layer of titanium oxide and hardly containednitrogen. It is thus presumable that nitrogen entered the sample fromthe atmosphere during the baking. In addition, the formation of themetal compound layer 105 containing nitrogen probably can reduce theforce required for peeling.

Example 4

In this example, results of peeling a resin layer from a formationsubstrate by the peeling method of one embodiment of the presentinvention will be described.

<Sample Fabrication>

The results in Example 3 suggested that the nitrogen contained in themetal compound layer 105 is supplied at the timing of the baking in anitrogen-containing atmosphere. In view of the above, in Sample D ofthis example, baking was performed on the metal layer 102 in anitrogen-containing atmosphere before the first layer 122 to be theresin layer 123 was formed, to form the metal compound layer 105.Furthermore, an acrylic resin having lower heat resistance than thepolyimide resin used in Example 1 was used as a material for the resinlayer 123, and baking at the time of the formation of the resin layer123 was performed at a temperature lower than that in Example 1. Such aSample D was formed and peelability was evaluated. Three of Samples Dwere fabricated; one was used for cross-sectional observation beforepeeling, another was used for XPS analysis after peeling, and the otherwas used for cross-sectional observation after peeling.

First, steps up to the step of forming the resin layer 123 over theformation substrate will be described with reference to FIG. 6, andthen, the steps after the formation of the resin layer 123 over theformation substrate will be described with reference to FIG. 2.

First, as illustrated in FIG. 6(A), the metal layer 102 was formed overthe formation substrate 101.

As the formation substrate 101, an approximately 0.7-mm-thick glasssubstrate was used. As the metal layer 102, an approximately 35-nm-thicktitanium film was formed by a sputtering method. At the time of theformation of the titanium film, an argon gas with a flow rate of 100sccm was used as the process gas, the pressure was 0.3 Pa, and the powerwas 58 kW.

Next, H₂O plasma treatment was performed on a surface of the metal layer102 to form a layer containing a metal oxide. In the H₂O plasmatreatment, the bias power was 4500 W, the ICP power was 0 W, thepressure was 15 Pa, the treatment time was 120 sec, and water vapor witha flow rate of 250 sccm was used as the process gas. In this example,the H₂O plasma treatment oxidized the surface side of the metal layer102. Thus, a stacked-layer structure of the titanium film over theformation substrate 101 and the titanium oxide film over the titaniumfilm was formed as the layer containing a metal oxide.

Next, the layer containing a metal oxide was subjected to baking in anitrogen-containing atmosphere (while a nitrogen gas was supplied) at450° C. for one hour, whereby the metal compound layer 105 was formed(FIG. 6(B1)).

Next, as illustrated in FIG. 6(C), the first layer 122 was formed overthe metal compound layer 105.

The first layer 122 was formed using a photosensitive materialcontaining an acrylic resin. The material was applied to a thickness ofapproximately 2 μm.

Next, the metal compound layer 105 and the first layer 122 weresubjected to baking in a nitrogen-containing atmosphere (while anitrogen gas was supplied) at 300° C. for one hour, whereby the metalcompound layer 105 and the resin layer 123 were formed (FIG. 6(D1)).

Next, as illustrated in FIG. 2(A), a UV-peeling tape (corresponding tothe adhesive layer 145 and the substrate 146 in FIG. 2(A)) was bondedonto the resin layer 123. Note that the functional layer 135 illustratedin FIG. 2(A) was not formed in this example.

<Cross-Sectional Observation of Sample Before Peeling>

Next, the results of cross-sectional STEM observation of Sample D beforepeeling will be described.

As shown in FIG. 32(A), it was found that the metal compound layer 105had a three-layer structure as shown in FIG. 6(D2). The metal compoundlayer 105 had a thickness of approximately 54 nm, the first compoundlayer 111 had a thickness of approximately 24 nm, the second compoundlayer 112 had a thickness of approximately 5 nm, and the third compoundlayer 113 had a thickness of approximately 25 nm.

<Peeling>

Next, as illustrated in FIG. 2(B), irradiation with the laser light 155was performed from the formation substrate 101 side. Then, the resinlayer 123 was peeled from the formation substrate 101.

As a laser oscillator for the laser light, a XeCl excimer laser with awavelength of 308 nm was used. The short-axis light-condensing width ofthe beam was 625 μm, the number of shots was 10, the repetition rate was60 Hz, the scanning speed was 3.75 mm/second, and the energy density wasapproximately 352 mJ/cm².

In Sample D, the resin layer 123 was peeled favorably. Note that peelingwas performed favorably in both the case where water was supplied froman end portion of the sample D before peeling and the case where it wasnot.

<Cross-Sectional Observation of Sample after Peeling>

Next, cross-sectional observation STEM of Sample D after peeling wasperformed. FIG. 32(B) shows cross-sectional observation results of theformation substrate 101 side of Sample D, and FIG. 32(C) showscross-sectional observation results of the substrate 146 side of SampleD.

From the results in FIGS. 32(A) and 32(B), no significant difference wasfound in the structure and thickness of the metal compound layer 105before and after the peeling. In FIG. 32(B), the metal compound layer105 had a thickness of approximately 47 nm, the first compound layer 111had a thickness of approximately 18 nm, the second compound layer 112had a thickness of approximately 6 nm, and the third compound layer 113had a thickness of approximately 23 nm.

As shown in FIG. 32(B), in Sample D, the resin layer 123 was notobserved between the metal compound layer 105 and a coat layer that wasformed for observation. As shown in FIG. 32(C), the metal compound layer105 was not observed between the resin layer 123 and the coat layer thatwas formed for observation. Thus, separation probably occurred betweenthe metal compound layer 105 and the resin layer 123 as illustrated inFIG. 2(C1).

<Depth-Direction Analysis of Sample after Peeling>

Next, XPS analysis was conducted on Sample D after peeling to obtain theproportions of oxygen atoms (O), titanium atoms (Ti), nitrogen atoms(N), and silicon atoms (Si) in the metal compound layer 105 in the depthdirection. Here, sputtering and measurement were performed from thesurface side of the metal compound layer 105 that was exposed bypeeling.

FIG. 33 shows the XPS analysis results of Sample D. In FIG. 33, thehorizontal axis represents the sputtering time (min), and the verticalaxis represents the quantitative value (atomic %).

From the XPS analysis results, it was checked that the metal compoundlayer 105 of Sample D had a three-layer structure as illustrated in FIG.6(D2).

From FIG. 33, it was found that a layer which had the highest oxygencontent among the layers included in the metal compound layer 105 wasthe first compound layer 111. The first compound layer 111 containedoxygen more than titanium. As shown in FIG. 33, the proportion of oxygencontained in the first compound layer 111 of Sample D was approximatelygreater than or equal to 50 atomic % and less than or equal to 70 atomic%. The proportion of titanium contained in the first compound layer 111of Sample D was approximately greater than or equal to 30 atomic % andless than or equal to 45 atomic %.

From FIG. 33, it was found that a layer which had the highest nitrogencontent among the layers included in the metal compound layer 105 wasthe second compound layer 112. As shown in FIG. 33, the proportion ofnitrogen contained in the second compound layer 112 of Sample D wasapproximately greater than or equal to 10 atomic % and less than orequal to 20 atomic %.

As shown in FIG. 33, the proportion of oxygen contained in the thirdcompound layer 113 of Sample D was approximately greater than or equalto 30 atomic % and less than or equal to 40 atomic %.

In addition, the metal compound layer 105 contained almost no silicon;specifically, the proportion of silicon contained in the first compoundlayer 111 was approximately less than or equal to 5 atomic %.

The results of the XPS analysis revealed that the first compound layer111 contained titanium oxide (TiO_(a) (a>1)), the second compound layer112 contained titanium oxynitride (TiO_(b)N_(e) (b>0, c>0)), and thethird compound layer 113 contained titanium oxide (TiO_(e) (0<e<a)).

It was checked from the results in this example that the formationsubstrate 101 can be peeled at the interface between the metal compoundlayer 105 and the resin layer 123 by the peeling method of oneembodiment of the present invention.

In the sample of this example, favorable separation was performedbetween the metal compound layer 105 and the resin layer 123. Before thefirst layer 122 to be the resin layer 123 was formed, baking wasperformed on the metal layer 102 in a nitrogen-containing atmosphere, sothat the metal compound layer 105 which is similar to those in Sample A1in Example 1 and Samples B1 and B2 in Example 2 was formed.Specifically, the cross-sectional observation and the XPS analysisshowed that the metal compound layer 105 had a three-layer structure andthe second compound layer 112 contained nitrogen sufficiently. Moreover,it was found that favorable peelability was achieved even when thetemperature applied to the resin layer 123 was lowered.

A sample was fabricated without performing the baking in anitrogen-containing atmosphere at 450° C. for one hour, which wasperformed for Sample D, in which case the peelability was poorer thanthat in Sample D. From the results of the XPS analysis, it was checkedthat the metal compound layer 105 of this sample hardly containednitrogen. Accordingly, it is presumable that by baking the layercontaining a metal oxide in a nitrogen-containing atmosphere to form themetal compound layer 105 containing nitrogen, the force required forpeeling can be reduced.

Example 5

In this example, results of peeling a functional layer from a formationsubstrate by the peeling method of one embodiment of the presentinvention will be described.

<Sample Fabrication>

First, steps before formation of a functional layer over a formationsubstrate will be described with reference to FIG. 7, and then, the stepof forming the functional layer over the formation substrate and thesubsequent steps will be described with reference to FIG. 2.

In this example, the metal compound layer 105 and the resin layer 123were formed to have an island-like shape. In this example, two kinds ofsamples (Sample E1 and Sample E2) which were different in the timing ofprocessing a film to be the metal compound layer 105 into an island-likeshape were fabricated.

First, as illustrated in FIGS. 7(A1) and 7(B1), the metal layer 102 wasformed over the formation substrate 101.

As the formation substrate 101, an approximately 0.7-mm-thick glasssubstrate was used. As the metal layer 102, an approximately 35-nm-thicktitanium film was formed by a sputtering method. At the time of theformation of the titanium film, an argon gas with a flow rate of 100sccm was used as the process gas, the pressure was 0.3 Pa, and the powerwas 58 kW.

Next, in Sample E1, H₂O plasma treatment was performed on a surface ofthe metal layer 102 (FIG. 7(B1)) to form the layer 103 containing ametal oxide (FIG. 7(C1)). In the H₂O plasma treatment, the bias powerwas 4500 W, the ICP power was 0 W, the pressure was 15 Pa, the treatmenttime was 600 sec, and water vapor with a flow rate of 250 sccm was usedas the process gas. In this example, the H₂O plasma treatment oxidizedthe surface side of the metal layer 102. Thus, a stacked-layer structureof the titanium film over the formation substrate 101 and the titaniumoxide film over the titanium film was formed as the layer 103 containinga metal oxide. Furthermore, a resist mask was formed over the layer 103containing a metal oxide, the layer 103 containing a metal oxide wasetched by a dry etching method, and then, the resist mask was removed,whereby the layer 103 containing a metal oxide was processed into anisland-like shape (FIG. 7(D1)).

In contrast, in Sample E2, the metal layer 102 was first processed intoan island-like shape by a dry etching method (FIG. 7(B2)). After that,H₂O plasma treatment was performed on a surface of the island-shapedmetal layer 102 (FIG. 7(C2)) to form the island-shaped layer 103containing a metal oxide (FIG. 7(D2)). Note that the conditions of theplasma treatment were similar to those of Sample E1.

Next, as illustrated in FIG. 7(E), the first layer 122 was formed overthe layer 103 containing a metal oxide.

The first layer 122 was formed using a photosensitive materialcontaining a polyimide resin precursor. The thickness at the time ofapplication of the material was approximately 3 μm.

Next, the layer 103 containing a metal oxide and the first layer 122were subjected to baking in a nitrogen-containing atmosphere (while anitrogen gas was supplied) at 450° C. for two hours, whereby the metalcompound layer 105 and the resin layer 123 were formed (FIG. 7(F)).

The subsequent steps will be described with reference to FIG. 2. Notethat the samples in this example are different from the stacked-layerstructure of FIG. 2 in that the metal compound layer 105 and the resinlayer 123 are formed in an island-like shape.

Next, as illustrated in FIG. 2(A), the functional layer 135 was formedover the resin layer 123, and a UV-peeling tape (corresponding to theadhesive layer 145 and the substrate 146 in FIG. 2(A)) was bonded ontothe functional layer 135.

As the functional layer 135, a stacked-layer structure including asilicon oxynitride film and a silicon nitride film was formed. Thethickness of the stacked-layer structure was approximately 650 nm.

<Peeling>

Next, as illustrated in FIG. 2(B), irradiation with the laser light 155was performed from the formation substrate 101 side. Then, the resinlayer 123 was peeled from the formation substrate 101.

As a laser oscillator for the laser light, a XeCl excimer laser with awavelength of 308 nm was used. The short-axis light-condensing width ofthe beam was 625 μm, the number of shots was 10, the repetition rate was60 Hz, the scanning speed was 3.75 mm/second, and the energy density wasapproximately 440 mJ/cm².

Before the peeling, water was supplied from an end portion of thesample.

In each of Sample E1 and Sample E2, the functional layer 135 wasfavorably peeled. In particular, the force required for peeling wassmaller in Sample E1 than in Sample E2. Accordingly, it was found thatthe force required for peeling can be smaller in the case where the H₂Oplasma treatment is performed to form the metal compound layer 105 andthen the metal compound layer 105 is processed than in the case wherethe H₂O plasma treatment is performed on the island-shaped metal layer102 to form the metal compound layer 105. This is probably because thedischarging conditions during the plasma treatment are different betweenbefore and after the processing of the metal layer 102 into anisland-like shape, leading to a difference in the oxidation state of thesurface of the metal layer 102. In other words, it is presumable thatthe metal layer 102 can be oxidized more uniformly and the forcerequired for peeling can be smaller in the case where the metal layer102 is oxidized before the metal layer 102 is processed into anisland-like shape (in a state before the metal layer 102 is patterned).

<Cross-Sectional Observation of Sample after Peeling>

Next, cross-sectional STEM observation of Sample E1 and Sample E2 afterpeeling was performed. FIG. 34(A) shows cross-sectional observationresults of the formation substrate 101 side of Sample E1; and FIG. 34(B)shows cross-sectional observation results of the formation substrate 101side of Sample E2.

As shown in FIGS. 34(A) and 34(B), it was found that the metal compoundlayer 105 had a three-layer structure as shown in FIG. 4(E2). The metalcompound layer 105 of Sample E1 had a thickness of approximately 48 nm,the first compound layer 111 had a thickness of approximately 16 nm, thesecond compound layer 112 had a thickness of approximately 9 nm, and thethird compound layer 113 had a thickness of approximately 23 nm. Themetal compound layer 105 of Sample E2 had a thickness of approximately43 nm, the first compound layer 111 had a thickness of approximately 10nm, the second compound layer 112 had a thickness of approximately 7 nm,and the third compound layer 113 had a thickness of approximately 26 nm.

As a result of the cross-sectional observation, the resin layer 123 wasnot observed between the metal compound layer 105 and the coat layerthat was formed for observation, in either Sample E1 or Sample E2. Thus,separation probably occurred between the metal compound layer 105 andthe resin layer 123 as illustrated in FIG. 2(C1).

It was checked from the results in this example that the formationsubstrate 101 can be peeled at the interface between the metal compoundlayer 105 and the resin layer 123 by the peeling method of oneembodiment of the present invention.

Example 6

In this example, results of peeling a functional layer from a formationsubstrate by the peeling method of one embodiment of the presentinvention will be described.

<Sample Fabrication>

First, steps before formation of a functional layer over a formationsubstrate in Sample F in this example will be described with referenceto FIG. 4, and then, the step of forming the functional layer over theformation substrate and the subsequent steps will be described withreference to FIG. 2.

First, as illustrated in FIG. 4(A), the metal layer 102 was formed overthe formation substrate 101.

As the formation substrate 101, an approximately 0.7-mm-thick glasssubstrate was used. As the metal layer 102, a titanium film was formedby a sputtering method. At the time of the formation of the titaniumfilm, an argon gas with a flow rate of 100 sccm was used as the processgas, the pressure was 0.3 Pa, and the power was 58 kW. The thickness ofthe titanium film of Sample F was approximately 35 nm.

Next, H₂O plasma treatment was performed on a surface of the metal layer102 (FIG. 4(B)) to form the layer 103 containing a metal oxide (FIG.4(C)). In the H₂O plasma treatment, the bias power was 4500 W, the ICPpower was 0 W, the pressure was 15 Pa, the treatment time was 600 sec,and water vapor with a flow rate of 250 sccm was used as the processgas. In this example, the H₂O plasma treatment oxidized the surface sideof the metal layer 102. Thus, a stacked-layer structure of the titaniumfilm over the formation substrate 101 and the titanium oxide film overthe titanium film was formed as the layer 103 containing a metal oxide.

Next, as illustrated in FIG. 4(D), the first layer 122 was formed overthe layer 103 containing a metal oxide.

The first layer 122 was formed using a photosensitive materialcontaining a polyimide resin precursor. The material was applied to athickness of approximately 3 μm.

Next, the layer 103 containing a metal oxide and the first layer 122were subjected to baking in a nitrogen-containing atmosphere (while anitrogen gas was supplied) at 450° C. for two hours, whereby the metalcompound layer 105 and the resin layer 123 were formed (FIG. 4(E1)).

Next, as illustrated in FIG. 2(A), the functional layer 135 was formedover the resin layer 123, and a resin film (corresponding to thesubstrate 146 in FIG. 2(A)) was bonded onto the functional layer 135with the use of the adhesive layer 145.

As the functional layer 135, a stacked-layer structure including aninorganic insulating film and a transistor was formed. A metal oxide wasused for a semiconductor layer of the transistor.

Next, as illustrated in FIG. 2(B), irradiation with the laser light 155was performed from the formation substrate 101 side. Then, the resinlayer 123 was peeled from the formation substrate 101.

As a laser oscillator for the laser light, a XeCl excimer laser with awavelength of 308 nm was used. The short-axis light-condensing width ofthe beam was 625 μm, the number of shots was 10, the repetition rate was60 Hz, the scanning speed was 3.75 mm/second, and the energy density wasapproximately 440 mJ/cm².

Note that water was fed to the peeling interface in the peeling.

In Sample F in this example, the functional layer 135 was favorablypeeled.

<ToF-SIMS Analysis of Sample after Peeling>

Next, Sample F after peeling was analyzed by ToF-SIMS. Here, whether ornot a peak attributed to titanium (Ti) is detected from a surface of theresin layer 123 exposed by peeling was checked. FIG. 35 shows results ofmeasurement by ToF-SIMS (the vertical axis: Count, the horizontal axis:m/z). The size of the measurement area was 200 μm×200 μm.

As shown in FIG. 35, a peak attributed to Ti was detected from thesurface of the resin layer 123.

Through the cross-sectional observation of Sample F which was subjectedto peeling by the peeling method of one embodiment of the presentinvention, no residue of the metal compound layer 105 was observed onthe surface of the resin layer 123; however, it was found that theresidue of the metal compound layer 105 can be observed by analysis ofthe surface of the resin layer 123.

Example 7

In this example, results of peeling a functional layer from a formationsubstrate by the peeling method of one embodiment of the presentinvention will be described.

First of all, a display device of a comparative example was fabricatedand the display state thereof was observed. First, a resin layer (apolyimide film) was formed over and in contact with a formationsubstrate (a glass substrate), and a layer to be peeled (including atransistor and a display element) was formed over the resin layer. Then,a step in which the layer to be peeled was peeled from the formationsubstrate by irradiation of the resin layer with laser light through theformation substrate was performed, so that the display device wasfabricated.

It was found from the results that when the energy density of the laserlight was too high, soot (an object like powder obtained bycarbonization of the resin) was likely to be generated.

It was also found that although generation of soot can be inhibited at alow energy density, a residue of the resin layer (the polyimide film) isgenerated over the formation substrate (the glass substrate), whichleads to a reduction in the yield of peeling.

In the case where the resin layer is formed over and in contact with theformation substrate as described above, the favorable range of laserlight irradiation conditions is narrow and is difficult to control insome cases.

In view of this, in this example, Sample G1 in which the resin layer wasformed over the formation substrate with the metal compound layertherebetween and Comparative sample G2 in which no metal compound layerwas formed and the resin layer was formed over and in contact with theformation substrate were fabricated, and surface observation of thesurfaces that were exposed by peeling was performed.

<Sample Fabrication>

A method for fabricating Sample G1 will be described with reference toFIGS. 36(A1), 36(B1), 36(C1), 36(D1), and 36(E1). A method forfabricating Comparative sample G2 will be described with reference toFIGS. 36(A2), 36(B2), 36(C2), 36(D2), and 36(E2).

First, as illustrated in FIG. 36(A1), the layer 103 containing a metaloxide was formed over the formation substrate 101 of Sample G1, and thefirst layer 122 was formed over the layer 103 containing a metal oxide.In contrast, in Comparative sample G2, the layer 103 containing a metaloxide was not formed, and as illustrated in FIG. 36(A2), the first layer122 was formed in contact with the formation substrate 101.

As the formation substrate 101, an approximately 0.7-mm-thick glasssubstrate was used.

The layer 103 containing a metal oxide of Sample G1 was formed in such amanner that the metal layer 102 was formed and H₂O plasma treatment wasperformed on a surface of the metal layer 102.

As the metal layer 102, a titanium film was formed by a sputteringmethod. At the time of the formation of the titanium film, an argon gaswith a flow rate of 100 sccm was used as the process gas, the pressurewas 0.3 Pa, and the power was 58 kW. The thickness of the titanium filmof Sample G1 was approximately 35 nm.

In the H₂O plasma treatment, the bias power was 4500 W, the ICP powerwas 0 W, the pressure was 15 Pa, the treatment time was 120 sec, andwater vapor with a flow rate of 250 sccm was used as the process gas.

The first layer 122 was formed using a photosensitive materialcontaining a polyimide resin precursor. The material was applied to athickness of approximately 2 μm.

Next, the layer 103 containing a metal oxide and the first layer 122 inSample G1 were subjected to baking in a nitrogen-containing atmosphere(while a nitrogen gas was supplied) at 450° C. for two hours, wherebythe metal compound layer 105 and the resin layer 123 were formed (FIG.36(B1)). In a similar manner, the first layer 122 in Comparative sampleG2 was subjected to baking in a nitrogen-containing atmosphere (while anitrogen gas was supplied) at 450° C. for two hours, whereby the resinlayer 123 was formed (FIG. 36(B2)).

Next, as illustrated in FIGS. 36(C1) and 36(C2), the functional layer135 was formed over the resin layer 123, and the substrate 146 wasbonded onto the functional layer 135 with the use of the adhesive layer145.

As the functional layer 135, a four-layer structure in which200-nm-thick silicon oxynitride films and 100-nm-thick titanium filmswere alternately stacked was formed. Note that the silicon oxynitridefilm was provided over the entire surface of a peeling region, and thetitanium film was provided in a layout intended for a wiring. Thethickness of the four-layer structure was approximately 600 nm.

A resin film was used as the substrate 146.

<Peeling>

Next, as illustrated in FIGS. 36(D1) and 36(D2), irradiation with thelaser light 155 was performed from the formation substrate 101 side.

As a laser oscillator for the laser light, a XeCl excimer laser with awavelength of 308 nm was used. The short-axis light-condensing width ofthe beam was 625 μm, the number of shots was 10, the repetition rate was60 Hz, the scanning speed was 3.75 mm/second, and the energy density wasapproximately 352 mJ/cm².

In the case of Sample G1, both the metal compound layer 105 and theresin layer 123 were irradiated with the laser light 155 (see aprocessing region 156 in FIG. 36(D1)). In the case of Comparative sampleG2, the resin layer 123 was irradiated with the laser light 155 (see theprocessing region 156 in FIG. 36(D2)).

Then, the functional layer 135 was peeled from the formation substrate101 as illustrated in FIGS. 36(E1) and 36(E2). Water was fed to thepeeling interface in the peeling.

As illustrated in FIG. 36(E1), separation occurred at the interfacebetween the metal compound layer 105 and the resin layer 123 in SampleG1. As illustrated in FIG. 36(E2), separation occurred in the resinlayer 123 in Comparative sample G2.

<Surface Observation of Sample after Peeling>

Next, surface observation of the surface exposed by peeling in eachsample (hereinafter also referred to as a peeling surface) was performedwith a scanning electron microscope (SEM). FIG. 37 shows SEM photographsof the peeling surfaces (Formation substrate 101 side and Substrate 146side) of the samples (Sample G1 and Comparative sample G2). FIG. 37(A)is the SEM photograph of the peeling surface of Sample G1 on theformation substrate 101 side. FIG. 37(B) is the SEM photograph of thepeeling surface of Sample G1 on the substrate 146 side. FIG. 37(C) isthe SEM photograph of the peeling surface of Comparative sample G2 onthe formation substrate 101 side. FIG. 37(D) is the SEM photograph ofthe peeling surface of Comparative sample G2 on the substrate 146 side.

At the time of the SEM observation, each sample was placed with thepeeling surface facing upward, and the observation was performed under acondition where the stage tilt angle was 30°.

Note that in each diagram, an upper region 10 is a surface exposed bypeeling, and a lower region 11 is a cut surface (partly including acrack) at the time of fabricating the sample for the SEM observation.

A comparison between the regions 10 in FIGS. 37(A) and 37(B) and theregions 10 in FIGS. 37(C) and 37(D) showed that the peeling surface ofSample G1 was less uneven than the peeling surface of Comparative sampleG2, with regard to each of the peeling surface on the formationsubstrate 101 side and the peeling surface on the substrate 146 side.

Soot was not observed through optical microscope observation ofComparative sample G2 but unevenness on the peeling surface observedthrough the SEM observation probably originated from finer soot.

When the peeling surface on the substrate 146 side has much unevennessand moreover, soot is generated, for example, display quality sometimesdecreases in the case where the peeling surface is positioned on thedisplay surface side of a display device. In addition, when the peelingsurface on the formation substrate 101 side has much unevenness andmoreover, soot is generated, the reuse of the formation substrate 101 isdifficult in some cases.

The above results suggested that when peeling is performed using themetal compound layer as in Sample G1, unevenness on the peeling surfaceand generation of soot can be inhibited and a reduction in displayquality of the display device can be inhibited. In addition, it wassuggested that peeling using the metal compound layer facilitates thereuse of the formation substrate.

Example 8

In this example, results of fabrication of transistors with the use ofone embodiment of the present invention and evaluation of theI_(d)-V_(g) characteristics and the reliability will be described.

First, a method for fabricating the transistor and results of theevaluation of the I_(d)-V_(g) characteristics of the transistor will bedescribed. Next, a method for fabricating a transistor and results ofthe evaluation of the reliability of the transistor will be described.

<Fabrication 1 of Transistor>

A method for fabricating the transistor of this example will bedescribed with reference to FIGS. 36(A1), 36(B1), 36(C1), 36(D1), and36(E1).

First, as illustrated in FIG. 36(A1), the layer 103 containing a metaloxide was formed over the formation substrate 101, and the first layer122 was formed over the layer 103 containing a metal oxide.

As the formation substrate 101, an approximately 0.7-mm-thick glasssubstrate was used.

The layer 103 containing a metal oxide was formed in such a manner thatthe metal layer 102 was formed and H₂O plasma treatment was performed ona surface of the metal layer 102.

As the metal layer 102, a titanium film was formed by a sputteringmethod. At the time of the formation of the titanium film, an argon gaswith a flow rate of 100 sccm was used as the process gas, the pressurewas 0.3 Pa, and the power was 58 kW. The thickness of the titanium filmwas approximately 35 nm.

In the H₂O plasma treatment, the bias power was 4500 W, the ICP powerwas 0 W, the pressure was 15 Pa, the treatment time was 600 sec, andwater vapor with a flow rate of 250 sccm was used as the process gas.

The first layer 122 was formed using a photosensitive materialcontaining a polyimide resin precursor. The material was applied to athickness of approximately 3 μm.

Next, the layer 103 containing a metal oxide and the first layer 122were subjected to baking in a nitrogen-containing atmosphere (while anitrogen gas was supplied) at 450° C. for two hours, whereby the metalcompound layer 105 and the resin layer 123 were formed (FIG. 36(B1)).

Next, as illustrated in FIG. 36(C1), the functional layer 135 was formedover the resin layer 123, and the substrate 146 was bonded onto thefunctional layer 135 with the use of the adhesive layer 145.

As the functional layer 135, the insulating layer 141 and the transistorover the insulating layer 141 were formed. The transistor is of atop-gate self-aligned (TGSA) type, like the transistor 210 illustratedin FIG. 16(A), and includes the conductive layer 201 functioning as aback gate in addition to the conductive layer 205 functioning as a gate.A CAC-IGZO was used for a semiconductor layer. The channel length of thetransistor was 2 μm and the channel width thereof was 2 μm.

A resin film was used as the substrate 146.

Next, as illustrated in FIG. 36(D1), irradiation with the laser light155 was performed from the formation substrate 101 side. Then, thefunctional layer 135 was peeled from the formation substrate 101 asillustrated in FIG. 36(E1). Water was fed to the peeling interface inthe peeling.

As a laser oscillator for the laser light, a XeCl excimer laser with awavelength of 308 nm was used. The short-axis light-condensing width ofthe beam was 625 μm, the number of shots was 10, the repetition rate was60 Hz, the scanning speed was 3.75 mm/second, and the energy density wasapproximately 352 mJ/cm².

<I_(d)-V_(g) Characteristics of Transistor>

FIG. 38 shows the I_(d)-V_(g) characteristics of the transistor beforeand after the peeling by the laser light irradiation. FIG. 38 shows theresults at V_(d)=0.1 V and V_(d)=10 V. In FIG. 38, a dotted line (dot)shows the results before the peeling (before separation) and a solidline (line) shows the results after the peeling (after separation). InFIG. 38, the I_(d)-V_(g) characteristics before and after the peelingsubstantially overlap with each other. As shown in FIG. 38, nosignificant change between before and after the peeling was observed,and normally-off characteristics were exhibited even with a channellength of 2 μm.

<Fabrication 2 of Transistor>

A method for fabricating the transistor of this example will bedescribed with reference to FIGS. 36(A1), 36(B1), 36(C1), 36(D1), and36(E1).

First, as illustrated in FIG. 36(A1), the layer 103 containing a metaloxide was formed over the formation substrate 101 and the first layer122 was formed over the layer 103 containing a metal oxide.

As the formation substrate 101, an approximately 0.7-mm-thick glasssubstrate was used.

The layer 103 containing a metal oxide was formed in such a manner thatthe metal layer 102 was formed and H₂O plasma treatment was performed ona surface of the metal layer 102.

As the metal layer 102, a titanium film was formed by a sputteringmethod. At the time of the formation of the titanium film, an argon gaswith a flow rate of 100 sccm was used as the process gas, the pressurewas 0.3 Pa, and the power was 58 kW. The thickness of the titanium filmwas approximately 35 nm.

In the H₂O plasma treatment, the bias power was 4500 W, the ICP powerwas 0 W, the pressure was 15 Pa, the treatment time was 120 sec, andwater vapor with a flow rate of 250 sccm was used as the process gas.

The first layer 122 was formed using a photosensitive materialcontaining a polyimide resin precursor. The material was applied to athickness of approximately 2 μm.

Next, the layer 103 containing a metal oxide and the first layer 122were subjected to baking in a nitrogen-containing atmosphere (while anitrogen gas was supplied) at 450° C. for two hours, whereby the metalcompound layer 105 and the resin layer 123 were formed (FIG. 36(B1)).

Next, as illustrated in FIG. 36(C1), the functional layer 135 was formedover the resin layer 123, and the substrate 146 was bonded onto thefunctional layer 135 with the use of the adhesive layer 145.

As the functional layer 135, the insulating layer 141 and the transistorover the insulating layer 141 were formed (see FIG. 39). The transistoris of a channel-etched type and has a dual-gate structure including theconductive layer 201 functioning as a gate and the conductive layer 205functioning as a back gate. A metal oxide layer 234 a includes CAC-IGZO,and a metal oxide layer 234 b includes CAAC-IGZO. The channel length ofthe transistor was 3 μm and the channel width thereof was 50 μm.

A water-soluble resin was used for the adhesive layer 145 and aUV-peeling tape was used for the substrate 146.

Next, as illustrated in FIG. 36(D1), irradiation with the laser light155 was performed from the formation substrate 101 side. Then, thefunctional layer 135 was peeled from the formation substrate 101 asillustrated in FIG. 36(E1). Water was fed to the peeling interface inthe peeling.

As a laser oscillator for the laser light, a XeCl excimer laser with awavelength of 308 nm was used. The short-axis light-condensing width ofthe beam was 625 μm, the number of shots was 10, the repetition rate was60 Hz, the scanning speed was 3.75 mm/second, and the energy density wasapproximately 360 mJ/cm².

After the peeling, the exposed resin layer 123 and the resin film werebonded to each other with the use of an adhesive. Next, ultravioletlight irradiation was performed from the substrate 146 side and thesubstrate 146 was peeled. Then, the adhesive layer 145 was removed bywashing with water.

<Gate Bias-Temperature Stress Test>

Next, a stress test was performed on the transistor after the peeling.As the stress test, a gate bias temperature (GBT) stress test was used.A GBT stress test is a kind of an accelerated test and can evaluate achange in transistor characteristics due to long-term use in a shorttime. Here, in the GBT stress test, a substrate over which thetransistor was formed was held at 60° C., a voltage of 0 V was appliedto a source and a drain of the transistor, and a voltage of 30 V or −30V was applied to a gate; this state was held for one hour. In this case,a test in which a positive voltage is applied to the gate is referred toas PBTS, and a test in which a negative voltage is applied to the gateis referred to as NBTS. A voltage of 30 V or −30 V was applied to thegate under light irradiation with a white LED at 10000 lx; this statewas held for one hour. In this case, a test in which a positive voltageis applied to the gate is referred to as PBITS, and a test in which anegative voltage is applied to the gate is referred to as NBITS.

FIG. 40 shows the results of the GBT stress test. FIG. 40 shows thatfavorable results were obtained in which the amount of change inthreshold value (ΔVth) was approximately smaller than or equal to ±1 V.This showed that a transistor having favorable characteristics can befabricated even when a peeling process is performed using one embodimentof the present invention.

Note that a factor of the favorable results obtained in the GBT stresstest is presumably as follows, for example: that the transistorincludes, as the metal oxide film, a stack of the CAC-OS film and theCAAC-OS film and thus a buried channel is formed, and that an influenceof defects and damage at an interface between the metal oxide film andthe insulating film at the back channel is reduced.

Example 9

In this example, results of fabrication of a flexible OLED display usingone embodiment of the present invention will be described.

<Fabrication of Flexible OLED Display>

A flexible OLED display fabricated in this example is an active matrixorganic EL display that has a display region with a diagonal of 8.67inches, 1080×1920 effective pixels, a resolution of 254 ppi, and anaperture ratio of 46.0%. The flexible OLED display includes a scandriver and is externally provided with a source driver by COF.

A channel-etched transistor using a CAC-OS was used as a transistor.

As a light-emitting element, a tandem (stacked-layer) organic EL elementemitting white light was used. The light-emitting element has atop-emission structure, and light from the light-emitting element isextracted to the outside of the display through a color filter.

The flexible OLED display of this example was fabricated usingFabrication method example 2 in Embodiment 3. Specifically, a formationsubstrate over which the transistor and the like were formed and aformation substrate over which the color filter and the like were formedwere bonded to each other and a peeling process was performed twice, sothat the transistor, the color filter, and the like were transferred toa film substrate.

A polyimide resin was used for the resin layer formed over the formationsubstrate where the transistor and the like were formed. The use of apolyimide resin having higher heat resistance than an acrylic resinallows the transistor to be formed at a relatively high temperature andcan improve the transistor characteristics.

An acrylic resin was used for the resin layer formed over the formationsubstrate where the color filter and the like were formed. The use of anacrylic resin having a higher visible-light-transmitting property than apolyimide resin enables high light extraction efficiency even when theresin layer remains.

Components on the formation substrate side where the color filter andthe like were formed will be described with reference to FIG. 42(A).Unlike in the structure illustrated in FIG. 15(A), the coloring layer197 and the light-blocking layer 198 were formed over and in contactwith the resin layer 123 a in this example. The coloring layer 197 andthe light-blocking layer 198 were covered with an overcoat 196, and theinsulating layer 191 was provided over the overcoat 196. In thisexample, an acrylic resin was used as the material for the overcoat 196,and a silicon nitride film was formed as the insulating layer 191.

The insulating layer 191 is positioned closer to the neutral plane ofthe flexible OLED display in the structure of FIG. 42(A) than in thestructure of FIG. 15(A). Therefore, generation of a display defect orthe like due to bending can be inhibited. Meanwhile, in the structure ofFIG. 15(A), the insulating layer 191 can be formed at high temperaturesregardless of the heat resistance of materials (e.g., a resin) used forthe coloring layer 197, the light-blocking layer 198, the overcoat, andthe like. Thus, depending on the materials for the layers, theinsulating layer 191 having a high barrier property might be more easilyobtained in the structure of FIG. 15(A) than in the structure of FIG.42(A).

FIG. 41(A) shows display results of the flexible OLED display fabricatedin this example. As shown in FIG. 41(A), display defects due to peelingby laser irradiation were not found, and normal light emission wasobserved.

<Repeated Bending Test>

Next, the flexible OLED display was subjected to a repeated bendingtest. The repeated bending test was performed with the use of abook-type repeated bend tester illustrated in FIGS. 42(B) and 42(C).FIG. 41(B) shows the state in which the bending test was performed.

The tester illustrated in FIGS. 42(B) and 42(C) includes a stage 311, astage 312, and a rotation axis 313. The stage 311 and the stage 312 areconnected by the rotation axis 313. A display panel 310 is positionedover the stage 311 and the stage 312. With a rotating mechanism of therotation axis 313, the stage 312 turns 180° from the state of FIG. 42(B)to the state of FIG. 42(C). Thus, the display panel 310 is bent with aradius of curvature R. Furthermore, the stage 312 turns 180° from thestate of FIG. 42(C) to the state of FIG. 42(B) with the rotatingmechanism. Thus, the display panel 310 is returned from the bent stateto a flat shape. The repeated bending test is performed by repeating thestate of FIG. 42(B) and the state of FIG. 42(C). The rate of the bendingtest was 2 seconds/time.

In this example, an outward bending test in which the display panel wasbent such that the display surface of the display panel faced outwardand an inward bending test in which the display panel was bent such thatthe display surface of the display panel faced inward were performed.Two radii of curvature R were set: 2.0 mm and 3.0 mm. The number oftimes of repeating bending in one test was 100000.

FIG. 41(C) shows a display photograph before the repeated bending test(Before bending test), and FIG. 41(D) shows a display photograph afterthe repeated bending test (After bending test). As shown in FIGS. 41(C)and 41(D), the Bended portion includes a display region. Even afterbending was repeated 100000 times with a radius of curvature of 2 mm,display defects due to bending were not found and normal light emissionwas observed. [Example 10]

In this example, results of fabrication of a flexible OLED display usingone embodiment of the present invention will be described.

<Fabrication of Flexible OLED Display>

A flexible OLED display fabricated in this example is an active matrixorganic EL display that has a display region with a diagonal of 8.34inches, 7680×4320 effective pixels (8K4K), a resolution of 1058 ppi, anda pixel size of 24 μm x 24 μm. The flexible OLED display includes a scandriver and is externally provided with a source driver IC.

A top gate self align (TGSA) transistor using a CAC-OS was used as atransistor.

As a light-emitting element, a tandem (stacked-layer) organic EL elementemitting white light was used. The light-emitting element has atop-emission structure, and light from the light-emitting element isextracted to the outside of the display through a color filter.

In the fabrication method of the flexible OLED display of this example,a formation substrate over which the transistor and the like were formedand a formation substrate over which the color filter and the like wereformed were bonded to each other and a peeling process was performedtwice, so that the transistor, the color filter, and the like weretransferred to a film substrate. In this example, one embodiment of thepresent invention was applied to the peeling process of the formationsubstrate over which the transistor and the like were formed.Specifically, the transistor, the light-emitting element, and the likewere formed over the formation substrate with a metal compound layer anda resin layer (a polyimide film) provided therebetween. Meanwhile, inthe peeling process of the formation substrate over which the colorfilter and the like were formed, an inorganic peeling layer (a tungstenoxide film) was used.

FIG. 43 shows display results of the flexible OLED display fabricated inthis example. As shown in FIG. 43, display defects due to peeling bylaser irradiation were not found, and normal light emission wasobserved.

DESCRIPTION OF NUMERALS

-   10 region-   11 region-   14 formation substrate-   20 metal compound layer-   23 resin layer-   26 linear beam-   27 processing region-   55 laser light-   56 stack-   56 a member to be peeled-   56 b support-   57 a first layer-   57 b second layer-   58 formation substrate-   59 stack-   101 formation substrate-   101 a formation substrate-   101 b formation substrate-   102 metal layer-   102 a metal layer-   103 layer containing metal oxide-   103 a layer containing metal oxide-   104 metal nitride layer-   105 metal compound layer-   105 a metal compound layer-   105 b metal compound layer-   110 plasma-   111 first compound layer-   111 a first compound layer-   112 second compound layer-   112 a second compound layer-   113 third compound layer-   113 a third compound layer-   122 first layer-   122 a first layer-   123 resin layer-   123 a resin layer-   123 b resin layer-   135 functional layer-   141 insulating layer-   145 adhesive layer-   146 substrate-   153 instrument-   154 region-   155 laser light-   156 processing region-   157 liquid feeding mechanism-   158 foreign matter-   159 region-   160 light-emitting element-   161 first electrode-   162 EL layer-   163 second electrode-   165 insulating layer-   167 insulating layer-   171 conductive layer-   172 auxiliary wiring-   173 conductive layer-   174 adhesive layer-   175 substrate-   176 adhesive layer-   177 substrate-   178 insulating layer-   181 conductive layer-   182 conductive layer-   183 conductive layer-   184 insulating layer-   185 insulating layer-   191 insulating layer-   195 adhesive layer-   196 overcoat-   197 coloring layer-   198 light-blocking layer-   201 conductive layer-   202 insulating layer-   203 a conductive layer-   203 b conductive layer-   204 semiconductor layer-   204 a channel region-   204 b low-resistance region-   205 conductive layer-   206 insulating layer-   207 insulating layer-   208 insulating layer-   209 insulating layer-   210 transistor-   211 insulating layer-   212 insulating layer-   213 insulating layer-   214 a channel region-   214 b low-resistance region-   214 c LDD region-   220 transistor-   224 semiconductor layer-   225 impurity semiconductor layer-   226 insulating layer-   230 transistor-   240 transistor-   600 tape-   601 support-   602 tape reel-   604 direction changing roller-   606 press roller-   606 a hollow cylinder-   606 b circular cylinder-   607 direction changing roller-   609 carrier plate-   610 laser irradiation unit-   610 a laser light-   610 b laser light-   610 c laser light-   610 d laser light-   610 e linear beam-   613 reel-   614 drying mechanism-   617 roller-   620 ionizer-   630 substrate reversing unit-   631 guide roller-   632 guide roller-   633 guide roller-   634 guide roller-   635 optical system-   639 ionizer-   640 processing region-   641 substrate load cassette-   642 substrate unload cassette-   643 transfer roller-   644 transfer roller-   645 transfer roller-   646 transfer roller-   650 mirror-   659 liquid feeding mechanism-   660 excimer laser apparatus-   665 guide roller-   666 guide roller-   670 separation tape-   671 support-   672 tape reel-   673 reel-   674 guide roller-   675 press roller-   676 direction changing roller-   677 guide roller-   678 guide roller-   679 guide roller-   680 lens-   683 reel-   7000 display portion-   7100 television device-   7101 housing-   7103 stand-   7111 remote controller-   7200 laptop personal computer-   7211 housing-   7212 keyboard-   7213 pointing device-   7214 external connection port-   7300 digital signage-   7301 housing-   7303 speaker-   7311 information terminal-   7400 digital signage-   7401 pillar-   7411 information terminal-   9000 housing-   9001 display portion-   9003 speaker-   9005 operation key-   9006 connection terminal-   9007 sensor-   9008 microphone-   9055 hinge-   9200 portable information terminal-   9201 portable information terminal-   9202 portable information terminal

This application is based on Japanese Patent Application Serial No.2017-050894 filed with Japan Patent Office on Mar. 16, 2017 and JapanesePatent Application Serial No. 2017-098999 filed with Japan Patent Officeon May 18, 2017, the entire contents of which are hereby incorporatedherein by reference.

What is claimed is:
 1. A light-emitting device comprising: a flexiblesubstrate; an adhesive layer over the flexible substrate; a resin layercontaining titanium over the adhesive layer; a first insulator over theresin layer; a first conductor over the first insulator; a secondinsulator over the first conductor; a semiconductor layer over thesecond insulator; a third insulator over the semiconductor layer; asecond conductor over the third insulator; a first electrode over thesecond conductor; an EL layer over the first electrode; and a secondelectrode over the EL layer.
 2. The light-emitting device according toclaim 1, wherein the semiconductor layer comprises a metal oxide, andwherein the resin layer comprises a polyimide resin.
 3. Thelight-emitting device according to claim 1, wherein the semiconductorlayer comprises hydrogenated amorphous silicon, and wherein the resinlayer comprises an acrylic resin.
 4. The light-emitting device accordingto claim 1, wherein the semiconductor layer comprises polysilicon, andwherein the resin layer comprises a polyimide resin.
 5. Thelight-emitting device according to claim 1, wherein the resin layercomprises a region with a thickness of greater than or equal to 0.1 μmand less than or equal to 5 μm.
 6. The light-emitting device accordingto claim 1, wherein the resin layer has an average transmittance oflight in a wavelength range of greater than or equal to 450 nm and lessthan or equal to 700 nm of 70% or higher.
 7. The light-emitting deviceaccording to claim 1, wherein titanium is detected in surface analysisof a surface of the resin layer on an adhesive layer side, and whereinthe surface analysis is performed by time-of-flight secondary ion massspectrometry.
 8. A light-emitting device comprising: a first flexiblesubstrate; a first adhesive layer over the first flexible substrate; afirst resin layer containing titanium over the first adhesive layer; afirst insulator over the first resin layer; a first conductor over thefirst insulator; a second insulator over the first conductor; asemiconductor layer over the second insulator; a third insulator overthe semiconductor layer; a second conductor over the third insulator; afirst electrode over the second conductor; an EL layer over the firstelectrode; a second electrode over the EL layer; a second adhesive layerover the second electrode; a coloring layer over the second adhesivelayer; a second resin layer over the coloring layer; a third adhesivelayer over the second resin layer; and a second flexible substrate. 9.The light-emitting device according to claim 8, wherein thesemiconductor layer comprises a metal oxide, and wherein the first resinlayer comprises a polyimide resin.
 10. The light-emitting deviceaccording to claim 8, wherein the semiconductor layer compriseshydrogenated amorphous silicon, and wherein the first resin layercomprises an acrylic resin.
 11. The light-emitting device according toclaim 8, wherein the semiconductor layer comprises polysilicon, andwherein the first resin layer comprises a polyimide resin.
 12. Thelight-emitting device according to claim 8, wherein the first resinlayer comprises a region with a thickness of greater than or equal to0.1 μm and less than or equal to 5 μm.
 13. The light-emitting deviceaccording to claim 8, wherein the first resin layer has an averagetransmittance of light in a wavelength range of greater than or equal to450 nm and less than or equal to 700 nm of 70% or higher.
 14. Thelight-emitting device according to claim 8, wherein titanium is detectedin surface analysis of a surface of the first resin layer on an adhesivelayer side, and wherein the surface analysis is performed bytime-of-flight secondary ion mass spectrometry.